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MULE 4010 TRANS4×4
DIESEL
Utility Vehicle
Service Manual
Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or procedure.
•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.
•Refer to the sectional table of contents for the exact pages to locate the specific topic required.
MULE 4010 TRANS4×4
DIESEL
Utility Vehicle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2008 Kawasaki Heavy Industries, Ltd.
5th Edition (1) : May 18, 2012
A
ABDC
AC
ATDC
BBDC
BDC g h
°F ft
L
BTDC
°C
DC
F
EUR
CA ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)
LIST OF ABBREVIATIONS
rpm
TDC
TIR
V
W
Ω
Pa
PS r psi lb m min
N pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)
Europe
Canada
COUNTRY AND AREA CODES
US United States
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. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow
-by gases are led to the breather chamber through the crankcase to the inlet manifold.
Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned to the bottom of the crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine family is engine modifications that consist of a modified injection pump and injection timing characteristics.
The fuel system has been calibrated to provide lean air/fuel mixture characteristics, with a suitable air cleaner and exhaust system.
A maintenance free injection system provides the most appropriate injection timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited.
(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”
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 devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10 000 PER VIOLATION.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
(US Model only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective inlet and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any way which results in an increase in noise level.
Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.
To get the longest life out of your vehicle.
•
Follow the Periodic Maintenance Chart in the
Service Manual.
•
Be alert for problems and non-scheduled maintenance.
•
Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
•
Follow the procedures in this manual carefully. Don’t take shortcuts.
•
Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual
In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want engine oil information, use the Quick Reference Guide to locate the Engine Lubrication System chapter. Then, use the Table of Contents on the first page of the chapter to find the Engine Oil section.
Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
This manual contains four more symbols which will help you distinguish different types of information.
NOTE
○
This note symbol indicates points of particular interest for more efficient and convenient operation.
•
Indicates a procedural step or work to be done.
○
Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of
Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the vehicle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable
(–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive
(+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.
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.
GENERAL INFORMATION 1-3
Storage of Removed Parts
After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
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 sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
Before Servicing
Press
For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
GENERAL INFORMATION 1-5
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from right side).
Electrical Wires
A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.
Model Identification
KAF950G9 Left Side View
GENERAL INFORMATION 1-7
KAF950G9 Right Side View
Frame Number Engine Number
1-8 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
KAF950G9
∼ GD/HA
(KAF950G9
∼ GC/HA) 3 305 (130.12 in.)
(KAF950GD) 3 265 mm (128.54 in.)
(KAF950G9
∼ GC/HA) 1 486 (58.50 in.)
(KAF950GD) 1 485 mm (58.46 in.)
1 925 mm (75.79 in.)
2 165 mm (85.24 in.)
Overall Height
Wheelbase
Track:
Front
Rear
Ground Clearance
Seat Height:
Front
Rear
Curb Mass:
Front
Rear
Fuel Tank Capacity
Cargo Bed (L × W × H):
Long Bed
1 160 mm (45.67 in.)
1 180 mm (46.46 in.)
180 mm (7.09 in.)
855 mm (33.66 in.)
880 mm (34.64 in.)
(KAF950G9
∼ GC/HA) 788 kg (1 738 lb)
(KAF950GD) 795 kg (1 753lb)
(KAF950G9
∼ GC/HA) 349 kg (770 lb)
(KAF950GD) 355 kg (783 lb)
(KAF950G9
∼ GC/HA) 439 kg (968 lb)
(KAF950GD) 440 kg (970 lb)
(KAF950G9
∼ GC/HA) 24.2 L (6.4 US gal.)
(KAF950GD) 24 L (6.3 US gal.)
Short Bed
(KAF950G9
∼ GC/HA) 1 280 × 1 212 × 287 mm (50.39 × 47.72 ×
11.30 in.)
(KAF950GD) 1 280 × 1 210 × 285 mm (50.39 × 47.64 × 11.22 in.)
(KAF950G9
∼ GC/HA) 770 × 1 212 × 287 mm (30.31 × 47.72 ×
11.30 in.)
(KAF950GD) 770 × 1 210 × 285 mm (30.31 × 47.64 × 11.22 in.)
Seating Capacity:
Front
Rear
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Injection Pump
Starting System
2
2
3.9 m (12.8 ft)
4-stroke, OHV, Diesel, 3-cylinders
Liquid-cooled
72 × 78 mm (2.83 × 3.07 in.)
953 cm³ (58.2 cu in.)
24.8
17.7 kW (24 PS) @3 600 r/min (rpm)
(CA), (US) – – –
52 N·m (5.3 kgf·m, 38.4 ft·lb) @2 800 r/min (rpm)
(CA), (US) – – –
Denso VE type
Electric starter
GENERAL INFORMATION 1-9
General Specifications
Items
Cylinder Numbering Method Right to left, 1-2-3
Firing Order Right to left, 1-2-3
Valve Timing:
Inlet:
Open
Close
10° BTDC
45° ABDC
235° Duration
Exhaust:
Open
Close
Duration
45° BBDC
10° ATDC
235°
KAF950G9
Forced lubrication (wet sump)
∼ GD/HA
Lubrication System
Engine Oil:
Grade
Viscosity
API CF or CF-4
SAE 10W-40
3.3 L (3.5 US qt) Capacity
Drive Train
Primary Reduction System:
Type Belt drive torque converter
3.7
∼ 0.98
Reduction Ratio
Transmission Gear Ratio:
Forward:
High
Low
1.821 (51/28)
3.750 (51/28 × 25/20 × 28/17)
Reverse:
Low
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio:
Forward:
High
Low
Reverse:
Low
4.220 (41/20 × 25/20 × 28/17)
Gear 4WD/2WD
5.429 (76/14)
9.690
19.950
22.454
Front Final Gear Case Oil:
Type
Viscosity
Capacity
Transmission Oil:
Type
Viscosity
Capacity
Hypoid gear oil for LSD (Limited Slip Differential gears)
SAE 140 (GL-5) or SAE 90 (GL-6)
0.4 L (0.4 US qt)
Hypoid gear oil
SAE 90: above 5°C (41°F) or
SAE 80: below 5°C (41°F)
2.5 L (2.6 US qt)
1-10 GENERAL INFORMATION
General Specifications
Items
Frame
Type
Caster (Rake Angle)
Camber
Trail
Tire:
Front and Rear
Rim Size:
Front and Rear
Steering Type
Suspension:
Front:
Type
Wheel Travel
Rear:
Type
Wheel Travel
Brake Type:
Front and Rear
Parking Brake Type
Electrical Equipment
Battery
Headlight:
Type
Bulb
Brake/Tail Light
Reverse Light
Alternator:
Type
Rated Output
Load Capacity
Maximum Vehicle Load
(Including Occupants and
Cargo)
Maximum Cargo Bed Load:
Long Bed
Short Bed
Steel tube, Ladder
7.5°
0.8°
35 mm (1.4 in.)
23 × 11.00-10, Tubeless
10 × 8.5 AT
Rack and pinion (Electric power steering)
MacPherson strut
100 mm (3.94 in.)
De Dion axle
70 mm (2.76 in.)
Drum (Hydraulic)
Drum (Mechanical internal expansion)
12 V 52 Ah
Semi-sealed beam
12 V 35 W × 2
12 V 21/5 W × 2
(EUR) 12 V 10 W
Three-phase AC
40 A, 12 V
740 kg (1 632 lb)
499 kg (1 100 lb)
318 kg (701 lb)
KAF950G9
∼ GD/HA
Specifications are subject to change without notice, and may not apply to every country.
Unit Conversion Table
Prefixes for Units:
Prefix mega kilo centi milli micro
Symbol
M k c m
µ
Power
× 1 000 000
× 1 000
× 0.01
× 0.001
× 0.000001
Units of Mass:
kg g
×
×
2.205
=
0.03527
= lb oz
Units of Volume:
L × 0.2642
=
L × 0.2200
=
L
L
L
L mL mL mL
×
×
×
×
×
×
×
1.057
=
0.8799
=
2.113
1.816
=
=
0.03381 =
0.02816 =
0.06102 =
Units of Force:
N × 0.1020
=
N × 0.2248
= kg kg
×
×
9.807
2.205
=
=
Units of Temperature:
gal (US) gal (IMP) qt (US) qt (IMP) pint (US) pint (IMP) oz (US) oz (IMP) cu in.
kg lb
N lb
GENERAL INFORMATION 1-11
Units of Length:
km m mm
×
×
×
0.6214
=
3.281
=
0.03937 =
Units of Torque:
N·m × 0.1020
=
N·m × 0.7376
=
N·m kgf·m kgf·m kgf·m
×
×
×
×
8.851
9.807
7.233
86.80
=
=
=
=
Units of Pressure:
kPa kPa kPa
×
×
×
0.01020 =
0.1450
=
0.7501
= kgf/cm² × kgf/cm² × cmHg ×
98.07
14.22
1.333
=
=
=
Units of Speed:
km/h × 0.6214
=
Units of Power:
kW kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
=
0.9863
=
=
= mile ft in.
PS
HP kW
HP kgf·m ft·lb in·lb
N·m ft·lb in·lb mph kgf/cm² psi cmHg kPa psi kPa
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
2
2-2 PERIODIC MAINTENANCE
Electrolyte Specific Gravity Inspection (Conventional Type Battery) ................................
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever First comes Service first After
Regular Service
Every Every Every Every
↓
→
50 h, or
1 000 km
100 h, or
2 000 km
250 h, or
5 000 km
500 h, or
10 000 km
800 h, or
16 000 km
See
Page
OPERATION
ENGINE
Every of use of use of use of use of use
Throttle pedal play - inspect
Idle speed - adjust
Fuel hoses and connections inspect*
Fuel hose - replace
•
•
•
•
•
•
2-14
2-15
2-15
Fuel filter element - replace*
5 years
Fuel filter water - drain*
Radiator - clean*
•
•
•
Radiator hoses and connections inspect*
Coolant - change
1 year
2 years
•
•
Cooling fan belt - inspect
Valve clearance - inspect*
•
Spark arrester - clean
Converter drive belt - inspect*
Converter drive belt deflection inspect*
•
•
•
•
Converter driven pulley shoe inspect*
•
Converter air cleaner element clean*
•
Engine oil - change*
Oil filter - replace
1 year
•
• •
•
: Clean, adjust, lubricate, torque, or replace parts as necessary.
•
•
*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
2-15
•
2-17
2-17
2-18
2-18
2-18
2-21
2-23
2-25
2-25
2-26
2-27
2-28
2-29
2-30
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever First
Regular Service comes Service first After Every Every Every Every
↓
Every
→
50 h, or
1 000 km
100 h, or
2 000 km
250 h, or
5 000 km
500 h, or
10 000 km
800 h, or
16 000 km of use of use of use of use of use OPERATION
CHASSIS
Front final gear case oil and transmission case oil - change*
1 year
•
Wheel nuts tightness - inspect
Tire wear - inspect*
Brake fluid level - inspect
•
•
•
•
•
•
•
Brake fluid - change 2 years
Brake pedal play - inspect*
• •
Brake master cylinder cup and dust seal - replace
2 years
Brake hose and pipe - inspect
• •
Brake hose - replace 4 years
Brake wear - inspect*
•
Brake wheel cylinder assembly replace
2 years
Parking brake lever - inspect
Steering - inspect
Steering joint dust boots - inspect
Seat belt - inspect
Battery - inspect (Note 1)
Brake light switch - inspect
General lubrication - perform*
Bolts, nuts, and fasteners tightness
- inspect
•
•
•
•
•
•
•
•
•
•
•
•
•
See
Page
2-35
2-35
2-36
2-37
2-38
2-40
2-42
2-42
2-43
2-43
2-45
2-46
2-47
•
: Clean, adjust, lubricate, torque, or replace parts as necessary.
*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
Note 1: Conventional Type Battery
2-30,
2-31
2-31
2-31
2-32
2-33
2-34
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.
Letters used in the “Remarks” column mean:
B: Apply brake fluid.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide grease oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Part
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
Fastener
N·m
Torque kgf·m ft·lb
Remarks
Fuel System
Air Cleaner Housing Mounting Bolts
Air Duct Mounting Bolt
Air Vent Plug
Distributor Head Bolt
Fuel Filter Mounting Bolts
Fuel Injection Nozzles
Fuel Injection Pipe Clamp Bolts
Fuel Injection Pipe Mounting Nuts
Fuel Injection Pump Bracket Bolts
Fuel Injection Pump Gear Nut
Fuel Injection Pump Mounting Nuts
Idle Adjusting Screw Locknut
Linkage Pipe Nuts
Maximum Speed Set Screw Locknut
Fuel Level Gauge Mounting Bolts (KAF950GD)
Cooling System
Coolant Drain Plug
Coolant Inlet Bolts
Coolant Reserve Tank Bolt
Coolant Temperature Switch
Fan Mounting Bolts
Radiator Fan Mounting Bolts
Radiator Fan Switch (KAF950GB
∼)
Radiator Fan Switch (KAF950G9
∼ GA/HA)
Radiator Mounting Bolts
Radiator Screen Mounting Bolts
Shroud Mounting Bolts
Thermostat Housing Cap Bolts
Water Pipe Mounting Bolts
Water Pump Mounting Bolts and Nuts
20
5.0
5.0
17
20
59
7.4
25
20
64
20
6.9
27
6.9
4.0
25
7.8
4.4
27
8.8
6.0
23
25
8.8
8.8
6.0
7.8
8.8
20
2.0
0.51
0.51
1.7
2.0
6.0
0.75
2.5
2.0
6.5
2.0
0.70
2.8
0.70
0.41
2.5
0.80
0.45
2.8
0.90
0.61
2.3
2.5
0.90
0.90
0.61
0.80
0.90
2.0
15
44 in·lb
44 in·lb
13
15
44
65 in·lb
18
15
47
15
61 in·lb
20
61 in·lb
35 in·lb
18
69 in·lb
39 in·lb
20
78 in·lb
53 in·lb
17
18
78 in·lb
78 in·lb
53 in·lb
69 in·lb
78 in·lb
15
L
L
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Engine Top End
Cylinder Head Bolts
Cylinder Head Cover Nuts
Exhaust Manifold Mounting Nuts
Inlet Manifold Mounting Bolts
Inlet Manifold Mounting Nuts
Rocker Arm Components Mounting Nuts
Valve Adjusting Screw Locknuts
Muffler Mounting Bolts
Converter System
Air Cleaner Housing Mounting Bolts
(KAF950GA/HA late models and KAF950GB
∼)
Air Cleaner Housing Mounting Bolts (KAF950G9 and KAF950GA/HA early models)
Converter Case Bolts (L = 55 mm)
Converter Case Bolts (L = 28 mm)
Converter Cover Bolts
Drive Pulley Bolt
Drive Pulley Cover Bolts
Driven Pulley Bolt
Fan Cover Bolts
Inner Cover Bolts
Inner Cover Nut
Ramp Weight Nuts
Spider
Wear Shoe Mounting Screws
Engine Lubrication System
Engine Oil Drain Plugs
Oil Filter Stud Bolt
Oil Nozzle
Oil Pan Bolts and Nuts
Oil Pressure Switch
Oil Pump Drive Gear Bolt
Oil Strainer Mounting Bolt and Nuts
Relief Valve Bolt
Engine Removal/Installation
Engine Mounting Bolts
Stay Rod Rear Nut
Crankshaft/Crankcase
Camshaft Drive Gear Bolt
Camshaft Retainer Bolts
Connecting Rod Cap Nuts
Coolant Drain Plug
N·m
34
5.4
20
7.8
7.8
20
11
20
16
20
13
93
8.8
4.4
27
20
4.4
93
8.8
6.9
275
1.1
7.8
14
20
7.8
39
34
44
14
44
88
43
7.8
36
25
Torque kgf·m
3.5
0.55
2.0
0.80
0.80
2.0
1.1
2.0
ft·lb
25
48 in·lb
15
69 in·lb
69 in·lb
15
97 in·lb
15
Remarks
EO, S
L
R
R
L
L
L
L
SS
L
12
15
20
15
39 in·lb
69
115 in·lb
69
78 in·lb
39 in·lb
78 in·lb
61 in·lb
203
10 in·lb
25
32
10
69 in·lb
10
15
69 in·lb
29
32
65
32
69 in·lb
27
18
1.6
2.0
2.8
2.0
0.45
9.5
1.3
9.5
0.90
0.45
0.90
0.70
28.0
0.11
3.5
4.5
1.4
0.80
1.4
2.0
0.80
4.0
4.5
9.0
4.4
0.80
3.7
2.5
Torque and Locking Agent
Fastener
Crankshaft Main Bearing Cap Bolts
Crankshaft Pulley Bolt
End Plate Bolts
Flywheel Mounting Bolts
Fuel Injection Pump Drive Gear Nut
Idle Gear Bolts
Oil Nozzle
Oil Pump Drive Gear Bolt
Oil Seal Retainer Bolts
Timing Gear Case Bolts
Timing Gear Case Cover Bolts
Transmission
Bearing Holder
Differential Gear Housing Bolts
Hi/Low Gear Case Bolts
Neutral Switch
Shift Arm Positioning Bolt
Shift Shaft Stop Bolt
Transmission Case Bolts
Transmission Case Mounting Nuts
Transmission Oil Drain Plug
Wheels/Tires
Wheel Nuts
Final Drive
Bearing Holder
Bevel Gear Case Bolts
Bevel Gear Case Holder Nuts
Differential Case Cap Bolts
Drive Gear Nut
Drive Shaft Cap Bolts
Driven Gear Shaft Nut
Front Axle Cap Bolts
Gear Case Bracket Bolts
Gear Case Mounting Nuts
Grease Nipple
Housing Locknut
Oil Drain Plug
Oil Filler Cap
Pinion Gear Bearing Housing Nuts
Pinion Gear Slotted Nut
Propeller Shaft Bearing Housing Cover Bolts
Ring Gear Bolts
Ring Gear Cover Bolts (M10)
PERIODIC MAINTENANCE 2-7
32
32
20 in·lb
87.0
15
21
18
87.0
87.0
16
18
24
87.0
15
79.7
78 in·lb
30 in·lb
61
35
87.0
42
15
11
27
69 in·lb
78 in·lb
32
11
101
32
47
18
10
ft·lb
44
72.3
29
15
48 in·lb
69 in·lb
69 in·lb
Remarks
EO
L, S
MO
L
R
L
L
MO
L
R
G
L
MO
L
12.0
5.8
2.0
1.5
3.8
0.80
0.90
4.5
1.5
14.0
Torque kgf·m
6.0
10.0
4.0
4.5
6.5
2.5
1.4
2.0
0.55
0.80
0.80
4.5
4.5
0.23
12.0
2.0
3.0
2.5
12.0
12.0
2.2
2.5
3.3
12.0
2.0
11.0
0.90
0.35
8.2
4.8
118
57
20
15
37
7.8
8.8
44
15
137
44
64
25
14
N·m
59
98
39
20
5.4
7.8
7.8
20
29
25
118
44
44
2.3
118
118
22
25
32
118
20
108
8.8
3.4
82
47
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Ring Gear Cover Bolts (M8)
Speed Sensor Bolt
Brakes
Bleed Valves
Brake Hose Banjo Bolts
Brake Pipe Nipples
Front Axle Nuts
Front Brake Panel Mounting Bolts
Front Wheel Cylinder Mounting Bolts
Master Cylinder Reservoir Cap
Piston Stop Bolt
Push Rod Locknut
Rear Axle Nuts
Rear Brake Panel Mounting Bolts
Rear Wheel Cylinder Mounting Nuts
Reservoir Clamp Bolt
Suspension
Damper Bracket Mounting Nuts
Front Suspension Arm Joint Nuts
Front Suspension Arm Pivot Bolts
Leaf Spring Mounting Bolts (Front)
Leaf Spring Mounting Nuts (Rear)
Rear Shock Absorber Mounting Nuts
Strut Clamp Nuts
Strut Locknuts
Strut Mounting Locknuts
Tie-Rod End Nuts
Steering
EPS Unit Mounting Bolts
Rack Guide Spring Cap Locknut
Steering Gear Assembly Bracket Bolts
Steering Wheel Mounting Nut
Strut Clamp Nuts
Tie-Rod End Locknuts
Tie-Rod End Nuts
Universal Joint Clamp Bolts
Frame
Battery Holder Mounting Nuts
Center Bar Mounting Bolts
Front Bar Mounting Bolts (Lower)
Front Bar Mounting Bolts (Upper)
Front Seat Bar Mounting Bolts
Hood Latch Lever Mounting Bolts
ft·lb
18
78 in·lb
Remarks
48 in·lb
18
13
145
32
91 in·lb
30 in·lb
78 in·lb
13
224
32
65 in·lb
54 in·lb
B
L
L
R, S
L
44
58
72.3
72.3
44
44
72.3
36
32
25
15
29
38
38
72.3
32
25
15
13
47
72.3
32
47
27
R
R
L
R
L
6.0
8.0
10.0
10.0
6.0
6.0
10.0
5.0
4.5
3.5
2.0
4.0
5.3
5.3
10.0
4.5
3.5
2.0
Torque kgf·m
2.5
0.90
0.90
1.8
31.0
4.5
0.75
0.62
0.55
2.5
1.8
20.0
4.5
1.1
0.35
1.7
6.5
10.0
4.5
6.5
3.8
98
59
59
98
59
78
98
49
44
34
52
98
44
34
20
20
39
52
17
64
98
44
64
37
N·m
25
8.8
8.8
17.2
304
44
7.4
6.1
5.4
25
18
196
44
10.3
3.4
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Rear Bar Mounting Bolts (Lower)
Rear Bar Mounting Bolts (Upper)
Rear Bar Mounting Nuts (Middle)
Rear End Subframe Mounting Nuts
Screen Fixing Lever Screws
Seat Belt Buckle Mounting Bolts
Seat Belt Mounting Bolts
Stay Rod Rear Nut
Tail Gate Fixing Lever Screws
Top Bar Mounting Bolts
Electrical System
Alternator Adjusting Bracket Bolts
Alternator Mounting Bolt
Alternator Pulley Locknut
Battery Holder Mounting Nuts
Connecting Plate Nuts
Coolant Temperature Switch
Glow Plugs
Neutral Switch
Oil Pressure Switch
Radiator Fan Switch (KAF950GB
∼)
Radiator Fan Switch (KAF950G9
∼ GA/HA)
Speed Sensor Bolt
Starter Motor End Cover Screws
Starter Motor Mounting Bolts
Starter Motor Through Bolts
44
4.4
34
34
N·m
64
44
44
88
4.4
44
14
23
25
8.8
1.5
39
9.3
1.2
27
17
15
20
39
11
17
Torque kgf·m
6.5
4.5
4.5
4.5
0.45
3.5
3.5
9.0
0.45
4.5
1.4
2.3
2.5
0.90
0.15
4.0
0.95
0.12
2.8
1.7
1.5
2.0
4.0
1.1
1.7
15
29
97 in·lb
13
11 in·lb
20
13
11
10
17
18
78 in·lb
13 in·lb
29
82 in·lb
ft·lb
47
32
32
32
39 in·lb
25
25
65
39 in·lb
32
Remarks
R
L
L
L
SS
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners of Engine Parts
Threads
Diameter
Mark of Torque
(mm)
6
8
6
6
8
10
10
bolt head
4T
7T
9T
4T
7T
4T
7T
N·m
3.9
∼ 4.9
7.8
∼ 9.8
12
∼ 15
10
∼ 14
18
∼ 22
20
∼ 24
39
∼ 44
kgf·m
0.40
∼ 0.50
0.80
∼ 1.0
1.2
∼ 1.5
1.0
∼ 1.4
1.8
∼ 2.2
2.0
∼ 2.4
4.0
∼ 4.5
ft·lb
35
∼ 43 in·lb
69
∼ 87 in·lb
104
∼ 130 in·lb
87
∼ 120 in·lb
13
∼ 16
14
∼ 17
29
∼ 33
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Basic Torque for General Fasteners of Frame Parts
Threads Diameter
(mm)
5
6
8
10
12
N·m
3.4
∼ 4.9
5.8
∼ 7.9
14
∼ 19
26
∼ 34
44
∼ 61
Torque kgf·m
0.35
∼ 0.50
0.60
∼ 0.80
1.4
∼ 1.9
2.6
∼ 3.5
4.5
∼ 6.2
ft·lb
30
∼ 43 in·lb
52
∼ 69 in·lb
10
∼ 14
19
∼ 25
33
∼ 45
PERIODIC MAINTENANCE 2-11
Specifications
Item
Fuel System
Throttle Pedal Play
Idle Speed
Cooling System
Coolant:
Type (Recommended)
Standard
5
∼ 10 mm (0.20 ∼ 0.39 in.)
850
∼ 950 r/min (rpm)
Service Limit
– – –
– – –
Color
Mixed Ratio
Freezing Point
Total Amount
Fan Belt Deflection
Engine Top End
Valve Clearance
Converter System
Belt Width
Belt Deflection
Wear Shoe Width
Engine Lubrication System
Engine Oil:
Grade
Viscosity
Capacity
Oil Level
Transmission
Transmission Oil:
Type
Viscosity
Capacity
Oil Level
Wheels/Tires
Tire Tread Depth
Final Drive
Front Final Gear Case Oil:
Type
Viscosity
Capacity
Oil Level
Permanent type of antifreeze
(soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)
Green
Soft water 50%, coolant 50%
–35°C (–31°F)
4.4 L (4.7 US qt)
9.5
∼ 11.5 mm (0.37 ∼ 0.45 in.) at 98 N (10 kgf, 22 lb)
0.20 mm (0.0079 in.)
34.1 mm (1.34 in.)
28
∼ 36 mm (1.10 ∼ 1.42 in.)
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
32.6 mm (1.28 in.)
– – –
16.4 mm (0.65 in.)
API CF or CF-4
SAE 10W-40
3.0 L (3.2 US qt) (When filter is not removed)
3.3 L (3.5 US qt) (When filter is removed)
Between F and L marks on dipstick
Hypoid gear oil
SAE 90: above 5°C (41°F) or
SAE 80: below 5°C (41°F)
2.5 L (2.6 US qt)
Between H and L level lines on dipstick
13.2 mm (0.52 in.)
Hypoid gear oil for LSD (Limited Slip
Differential gears)
SAE 140 (GL-5) or SAE 90 (GL-6)
0.4 L (0.4 US qt)
Filler opening level
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
3 mm (0.12 in.)
– – –
– – –
– – –
– – –
2-12 PERIODIC MAINTENANCE
Specifications
Brakes
Brake Fluid:
Item Standard
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.)
Brake Shoe Lining Thickness 4.5 mm (0.18 in.)
Parking Brake Lever Travel 8
∼ 12 notches (clicks) at 200 N (20 kgf, 44 lb)
Steering
Steering Wheel Free Play 0
∼ 20 mm (0 ∼ 0.79 in.)
Electrical System
Battery:
Capacity
Voltage
Electrolyte Level*
Specific Gravity*
12 V 52 Ah
12.6 V or more
Between upper and lower level
1.265 at 20°C (68°F)
Switches:
Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel
*: Conventional Type Battery
Service Limit
– – –
– – –
– – –
180.75 mm
(7.116 in.)
1.0 mm (0.04 in.)
– – –
– – –
– – –
– – –
– – –
– – –
– – –
Special Tools
Inside Circlip Pliers:
57001-143
PERIODIC MAINTENANCE 2-13
Flywheel & Pulley Holder:
57001-1605
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Throttle Pedal 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 and link (see Throttle Cable Lubrication in the Fuel System chapter).
•
Check the throttle pedal play [A].
Throttle Pedal Play
Standard: 5
∼ 10 mm (0.20 ∼ 0.39 in.)
If the play is incorrect, adjust the throttle cable.
•
Throttle Pedal Play Adjustment
Tilt up the cargo bed.
•
Loosen the adjuster mounting nuts [A] at the engine end of the cable.
•
•
Slide the adjuster [B] until the proper amount of throttle pedal play is obtained.
•
Tighten the adjuster mounting nuts securely.
•
Start the engine.
With the transmission in neutral, operate the throttle pedal a few times to make sure that the idle speed does not change.
If the idle speed does change, the throttle cable may be improperly adjusted, incorrectly routed, or it may be damaged.
•
Correct any of these conditions before operation.
WARNING
Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions.
NOTE
○
If the throttle pedal play can not be adjusted by using the adjuster at the engine end of the cable, use the cable adjuster [A] at the throttle pedal. Do not forget to securely tighten the adjuster mounting nuts [B].
Periodic Maintenance Procedures
•
Idle Speed Inspection
Start the engine and warm it up thoroughly.
•
Tilt up the cargo bed.
•
Check the idle speed with a suitable tachometer [A].
Tachometer Adapter [B]
Idle Speed
Standard: 850
∼ 950 r/min (rpm)
If the idle speed is out of the specified range, adjust it.
PERIODIC MAINTENANCE 2-15
•
Idle Speed Adjustment
Start the engine and warm it up thoroughly.
•
Loosen the locknut [A].
•
Turn the idle adjusting screw [B] at the injection pump until the idle speed is correct.
•
Tighten:
Torque - Idle Adjusting Screw Locknut: 6.9 N·m (0.70
kgf·m, 61 in·lb)
•
Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.
•
Fuel Hoses and Connections Inspection
Tilt up the cargo bed and seat.
•
Check the fuel hoses and fittings for deterioration, cracks and signs of leakage.
Replace the fuel hose if any fraying, leak [A], cracks [B] or bulges [C] are noticed.
•
Check that the hoses are securely connected and clamps are installed correctly.
•
When installing, run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
•
When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.
•
Fuel Hoses Replacement
Tilt up the cargo bed and seat.
•
Remove:
Front Seat Lower Cover Front (see Floor Center Panel
Removal in the Frame chapter)
Clamps [A]
Fuel Hoses [B]
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Remove:
Clamps [A]
Fuel Hoses [B]
•
Remove:
Clamps [A]
Fuel Hoses [B]
•
Remove:
Clamp [A]
Fuel Hose [B]
Fuel Filter Mounting Bolts [C]
•
Remove:
Clamps [A]
Fuel Hoses [B]
•
When installing, run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
•
When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and run the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.
Periodic Maintenance Procedures
•
Fit the fuel hose [A] onto the fitting fully and install the plate clamp [B] beyond the raised rib [C].
1
∼ 2 mm (0.039 ∼ 0.079 in.) [D]
○
The hose end must reach the filler [E] or be as near as possible to the step [F].
PERIODIC MAINTENANCE 2-17
•
Bleed the air from the fuel filter (see Fuel Filter Installation in the Fuel System chapter).
Fuel Filter Element Replacement
•
Remove:
Fuel Filter (see Fuel Filter Removal in the Fuel System chapter)
Drain Cap [A]
O-ring [B]
Filter Cartridge [C]
○
Use a suitable filter wrench.
•
Install a new filter cartridge by hand until the gasket contacts the housing. Then tighten it 1/3 turn more.
•
Install:
Drain Cap
New O-ring
Fuel Filter (see Fuel Filter Installation in the Fuel System chapter)
•
Fuel Filter Water Draining
Tilt up the cargo bed.
•
Place a suitable container under the filter drain hose [A].
•
Loosen the air vent plug [B].
•
Loosen the drain cap [C] approximately 1 turn, and drain water from the filter until only fuel flows from the filter.
•
Tighten the drain cap securely.
•
Bleed the air from the fuel filter (see Fuel Filter Element
Replacement).
○
Wipe off any spilled fuel.
•
Start the engine, and check for fuel leakage.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Cooling System
Radiator Cleaning
NOTICE
Clean the radiator screen and the radiator in accordance with the Periodic Maintenance Chart.
In dusty areas, they should be cleaned more frequently than the recommended interval.
After riding through muddy terrain, the radiator screen and the radiator should be cleaned immediately.
•
Remove:
Front Cover (see Front Cover Removal in the Frame chapter)
Radiator Screen Mounting Bolts [A]
Radiator Screen [B]
•
Clean the radiator screen in a bath of tap water, and then dry it with compressed air or by shaking it.
NOTICE
When cleaning the radiator with a steam cleaner, be careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular to the core surface.
Run the steam gun following the core fin direction.
•
Install the radiator screen.
•
Tighten:
Torque - Radiator Screen Mounting Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)
Radiator Hose and Connection Inspection
○
The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.
•
Check that the hoses are securely connected and clamps are tightened correctly.
Coolant Change
WARNING
Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.
Periodic Maintenance Procedures
•
Tilt up the front cargo hood.
•
Remove:
Quick Rivets [A]
Tapping Screw [B] and Collar
Partition [C]
•
•
Remove the coolant reserve tank mounting bolts [A].
•
Remove the cap [B] and poor the coolant into a container.
Install the removed parts except the cap.
PERIODIC MAINTENANCE 2-19
•
Remove the front final gear case skid plate (see Front
Final Gear Case Oil Level Inspection in the Final Drive
• chapter).
Place a container under the drain plugs.
•
Remove the coolant drain plugs [A] at water pipes.
•
Place a funnel under the drain hole.
•
Remove the radiator cap [A] in two steps.
○
First turn the cap counterclockwise to the first step.
○
Then push and turn it further in the same direction and remove the cap.
•
Tighten the drain plugs.
•
Install the reserve tank hose and reserve tank.
•
Tighten:
Torque - Coolant Reserve Tank Bolt: 4.4 N·m (0.45 kgf·m,
39 in·lb)
•
Lift the front wheels 20
∼ 30 cm (7.9 ∼ 11.8 in.) from the ground so that the radiator cap is the highest port of the system.
•
Pour the coolant slowly into the radiator cap fitting.
NOTE
○
Pour in the coolant slowly so that the air in the engine and radiator can escape.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Front [A]
Air Bleeder Bolt [B]
Radiator Cap [C]
Reserve Tank Cap [D]
NOTICE
Soft or distilled water must be used with antifreeze in the cooling system.
If hard water is used in the system, it causes scale accumulation in the water passages, considerably reducing the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water: 50%
Coolant: 50%
Freezing Point: –35°C (–31°F)
Total Amount: 4.4 L (4.7 US qt)
NOTE
○
Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.
•
When the coolant begins to flow out the air bleeder bolt holes, tighten the air bleeder bolt.
•
Fill the cooling system up to the filler neck [A] in the radiator cap fitting with coolant.
Periodic Maintenance Procedures
•
Bleed the air from the cooling system as follows.
○
Start the engine and run it until no more air bubbles [A] can be seen in the coolant (less than five minutes).
○
Tap the radiator hoses to force any air bubbles caught inside.
○
Stop the engine and add coolant up to the filler neck.
•
Install the radiator cap.
•
Lower the front wheels slowly.
PERIODIC MAINTENANCE 2-21
•
Fill the reserve tank up to the F (full) level line [A] with coolant.
NOTICE
Do not add more coolant above the F (full) level line.
•
Install the reserve tank cap [B].
•
Cooling Fan Belt Inspection
Tilt up the cargo bed.
•
Remove:
Rear Propeller Shaft (see Propeller Shaft Removal in the
Final Drive chapter)
Water Pipe [A] and Water Hose [B]
•
Remove the fan cover bolts [A].
•
Take off the fan cover [A].
•
Rotate the fan blade [B], and position it as shown in the figure.
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Remove the fan cover [A] as shown in the figure.
•
Remove:
Fan Mounting Bolts [A]
Cooling Fan [B]
Spacer
•
Reinstall the spacer [A] and tighten the fan mounting bolts
[B] temporary.
Torque - Fan Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
•
Remove:
Bolts [A]
Fan Belt Cover [B]
•
Check the cooling fan belt [A] for excessive wear crack or broken.
If necessary, replace the belt with a new one.
Periodic Maintenance Procedures
•
Check the fan belt deflection.
○
Use a ruler [A], push the belt with 98 N (10 kgf, 22 lb) force.
Push Gauge [B]
PERIODIC MAINTENANCE 2-23
Fan Belt Deflection
Standard: 9.5
∼ 11.5 mm (0.37 ∼ 0.45 in.)
If the deflection is incorrect, adjust it.
•
Loosen the alternator adjusting bracket bolt [A] and alternator mounting bolt [B].
•
Alternator [C]
Adjust the fan belt deflection.
○
Use a ruler, push the belt with 98 N (10 kgf, 22 lb) force.
•
Tighten the bolts.
Torque - Alternator Adjusting Bracket Bolts: 20 N·m (2.0
kgf·m, 15 ft·lb)
Alternator Mounting Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
•
When installing the water pipe and water hose, note the following.
○
Check that the damper [A] is in place on the water pipe
[B].
Air Bleed Bolt [C]
5
∼ 10 mm (0.20 ∼ 0.40 in.) [D]
If the damper is damaged or deteriorated, replace it.
○
Insert the water pipe [A] up to the end of the bending radius of the water hose [B] as shown in the figure.
Air Bleed Bolt [C]
○
Make sure that there is clearance between the water pipe and the fan cover.
Engine Top End
Valve Clearance Inspection
NOTE
○
Valve clearance must be checked when the engine is cold (at room temperature).
•
Remove:
Fan Belt Cover (see Cooling Fan Belt Inspection)
Cylinder Head Cover (see Rocker Arm Components Removal in the Engine Top End chapter)
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Turn the crankshaft pulley [A] clockwise so that the timing mark [B] on the pulley aligns with the reference point [C] on the timing gear case cover.
○
Check that the rocker arms at #1 cylinder are free.
If not, turn the pulley one more turn to free the rocker arms.
•
Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the valve stem cap [C].
If the valve clearance is incorrect, adjust it.
Valve Clearance
Standard: 0.20 mm (0.0079 in.)
○
When positioning #1 piston TDC at the compression stroke:
Inlet valve clearance of #1 and #3 cylinders
Exhaust valve clearance of #1 and #2 cylinders
Front [A]
Measuring Valve [B]
○
Turn the crankshaft pulley 360° clockwise.
Inlet valve clearance of #2 cylinder
Exhaust valve clearance of #3 cylinder
Front [A]
Measuring Valve [B]
•
Valve Clearance Adjustment
Loosen the valve adjusting screw locknut [A].
•
Turn the valve adjusting screw [B] until the correct clearance is obtained.
•
Holding the adjusting screw, tighten the locknut.
Torque - Valve Adjusting Screw Locknuts: 11 N·m (1.1
kgf·m, 97 in·lb)
Periodic Maintenance Procedures
Spark Arrester Cleaning
WARNING
The muffler can become extremely hot during normal operation and cause severe burns. Since the engine must be running during this procedure, wear heat-resistant gloves while cleaning the spark arrester.
•
•
Remove the drain plug [A] from the muffler [B].
Apply the parking brake.
•
In an open area away from combustible materials, start the engine with the gear shift lever in the N (neutral) position.
•
Raise and lower engine speed while tapping on the muffler with a rubber mallet until the carbon particles are purged from the muffler.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.
Inhaling carbon monoxide can cause serious brain injury or death.
DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area.
•
Stop the engine.
•
Install the drain plug.
Converter System
Drive Belt Inspection
•
Remove the drive belt (see Drive Belt Removal in the
Converter System chapter).
•
Measure the width [A] of the belt.
If any measurements exceed the service limit, replace the belt.
Belt Width
Standard: 34.1 mm (1.34 in.)
Service Limit: 32.6 mm (1.28 in.)
•
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.
PERIODIC MAINTENANCE 2-25
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Belt Deflection Inspection
•
Remove the torque converter inner cover (see Torque
Converter Inner Cover Removal in the Converter System chapter).
•
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 belt deflection as shown in the figure.
○
Place a straightedge [A] on top of the belt between the drive pulley [B] and the driven pulley [C].
○
Use a ruler to push the belt away from the straightedge.
Push hard, but with no more force than 59 N (6 kgf, 13 lb).
Belt Deflection
Standard: 28
∼ 36 mm (1.10 ∼ 1.42 in.)
If the belt deflection is not within the specified range, first measure the drive belt width (see Drive Belt Inspection).
Adjust the deflection by adding or removing spacers between the driven pulley shaft hub and cam ramp.
•
When adjusting the deflection, less is better than more.
Less deflection will maintain better performance for more time as the belt width decreases by normal wear, which causes the deflection to increase with usage.
Periodic Maintenance Procedures
Drive Belt Deflection Adjustment
•
Disassemble the driven pulley [A] (see Driven Pulley Disassembly in the Converter System chapter).
If the belt deflection is more than 36 mm (1.42 in.), remove the spacers to decrease it.
○
The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.4 mm (0.055 in.) change in belt deflection.
If the belt deflection is less than 28 mm (1.10 in.), add the spacers [B] to increase it.
○
The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.6 mm (0.063 in.) change in belt deflection.
Spacers
Thickness
0.3 mm (0.012 in.)
0.6 mm (0.024 in.)
0.8 mm (0.031 in.)
Part No.
92026-0036
92026-1626
92026-1628
1.0 mm (0.039 in.) 92026-1625
1.4 mm (0.055 in.) 92026-1627
•
Assemble the driven pulley (see Driven Pulley Assembly in the Converter System chapter).
•
With the transmission in neutral, rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection.
•
Measure the belt deflection again and repeat the above procedures until it is within the standard range.
•
Using the flywheel & pulley holder, apply a non
-permanent locking agent to the driven pulley bolt and tighten it.
Special Tool - Flywheel & Pulley Holder: 57001-1605
Torque - Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
Converter Driven Pulley Shoe Inspection
•
Disassemble the driven pulley (see Driven Pulley Disassembly in the Converter System chapter).
If the cams [A] of ramp [B] or the wear shoes [C] are damaged or worn, replace the ramp or the wear shoes.
PERIODIC MAINTENANCE 2-27
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If the wear shoe contact area width [A] is greater than the service limit, replace the shoe [B].
Wear Shoe Width
Service Limit: 16.4 mm (0.65 in.)
Converter Air Cleaner Element Cleaning/Inspection
NOTE
○
In dusty areas, the element should be cleaned more frequently than the recommended interval.
○
After riding through rain or on muddy roads, the element should be cleaned immediately.
WARNING
Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low flash-point solvents to clean the element.
•
Remove the air cleaner element (see Air Cleaner Element
Removal in the Converter System chapter).
•
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.
•
After cleaning, saturate the foam element with SE class
SAE30 oil, squeeze out the excess, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the foam element.
•
Clean the paper element by tapping gently.
NOTICE
Do not use compressed air to clean the paper element.
Do not oil the paper element.
Periodic Maintenance Procedures
Engine Lubrication System
•
Engine Oil and/or Oil Filter Change
•
Warm up the engine so that the oil will pick up any sediment and drain easily.
•
Place an oil pan beneath the engine.
Remove the engine oil drain plug [A], and let the oil drain completely.
If the oil filter is to be changed, replace it with a new one
•
(see Oil Filter Removal/Installation).
Replace the gasket with a new one.
•
After the oil has completely drained out, install the drain plug with the gasket.
Torque - Engine Oil Drain Plugs: 34 N·m (3.5 kgf·m, 25 ft·lb)
NOTICE
To avoid engine damage, do not fill the engine oil above the full level. If the oil level in the cylinder head cover gets too high because of filling too fast, oil may over flow from the filler opening and/or may flow through the crankcase breather hose into the inlet manifold. Oil in the inlet manifold may flow into the combustion chambers and cause hydraulic lock, resulting in severe engine damage.
•
Remove the oil filler cap, and pull the dipstick out a little
(about 5 cm, 2 in.) to allow the air in the crankcase to escape.
•
Slowly and evenly fill the engine with a good quality oil as specified in the table.
•
Check the oil level.
Engine Oil
Grade: API CF or CF-4
Viscosity: SAE 10W-40
Capacity: 3.0 L (3.2 US qt )
(When filter is not removed)
3.3 L (3.5 US qt )
(When filter is removed)
Oil Level:
Between F and L marks on dipstick
NOTE
○
Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.
PERIODIC MAINTENANCE 2-29
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Oil Filter Removal
Tilt up the cargo bed.
•
Remove the oil filter [A] from under the vehicle.
○
When unscrewing the oil filter, cover the filter bottom with a clean cloth so as not to spill the engine oil out of the filter. Any spilled oil should be wiped up completely.
•
Oil Filter Installation
Apply engine oil to the oil filter gasket.
•
Install a new filter.
○
Screw the filter in until the gasket touches the engine, then turn it 1 turn.
•
Add the engine oil (see Engine Oil and/or Oil Filter
Change).
•
Thoroughly warm up the engine, and check for oil leakage and the oil level.
If necessary, add more engine oil.
Transmission
Transmission Oil Change
•
Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the
• vehicle.
Place an oil pan beneath the transmission case.
•
Remove the transmission oil drain plug [A], and let the oil drain completely.
•
Replace the gasket with a new one.
•
After the oil has completely drained out, install the drain plug with the gasket.
Torque - Transmission Oil Drain Plug: 15 N·m (1.5 kgf·m,
11 ft·lb)
•
Fill the transmission case with a good quality oil as specified in the table.
•
Check the oil level.
Transmission Oil
Type: Hypoid gear oil
Viscosity: SAE 90: above 5°C (41°F) or
SAE 80: below 5°C (41°F)
Capacity: 2.5 L (2.6 US qt)
Oil Level: Between H and L level lines on dipstick
Periodic Maintenance Procedures
Wheels/Tires
Wheels Nuts Tightness Inspection
•
Check the tightness of all the wheel nuts.
If there are loose nut, first loosen by 1/2 turn, then retorque them to the specified torque.
Torque - Wheel Nuts: 137 N·m (14.0 kgf·m, 101 ft·lb)
○
Tighten the wheel nuts [1]
∼ [4] in a criss-cross pattern.
PERIODIC MAINTENANCE 2-31
Tire Wear Inspection
•
Examine the tire for damage and wear.
If the tire is cut or cracked, replace it.
○
Lumps or high spots on the tread or sidewalls indicate internal damage, requiring tire replacement.
○
Remove any foreign objects from the tread. After removal, check for leaks with a soap and water solution.
•
Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurements at several places.
If any of the measurements is less than the service limit, replace the tire.
Tire Tread Depth
Standard: 13.2 mm (0.52 in.)
Service Limit 3 mm (0.12 in.)
Standard Tire
Front and Rear: 23 × 11.00-10 DUNLOP KT869 Tubeless
Final Drive
Front Final Gear Case Oil Change
•
Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle.
•
Park the vehicle so that it is level, both side-to-side and front-to-rear.
•
Remove the front final gear case skid plate (see Front
Final Gear Case Oil Level Inspection in the Final Drive chapter).
•
Place an oil pan beneath the front final gear case and remove the drain plug [A].
WARNING
Oil on tires can cause loss of traction and an accident resulting in serious injury or death. When draining or filling the final gear case, do not spill oil the tire or rim. Clean any oil that may spill with a high flash-point solvent.
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
After the oil has completely drained out, install the drain plug with a new aluminum gasket, and tighten it.
Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
•
Fill the gear case up to the bottom [A] of filler opening [B] with the oil specified below.
Front Final Gear Case Oil
Type: Hypoid gear oil for LSD (Limited Slip
Differential gears)
Viscosity: SAE 140 (GL-5) or SAE 90 (GL-6)
Capacity: 0.4 L (0.4 US qt)
Oil Level: Filler opening level
NOTE
○
“GL-5 or GL-6” indicate a quality and additive rating.
•
Be sure the O-ring [A] is in place, and tighten the filler cap.
Filler Opening [B]
Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 21 ft·lb)
•
Install the front final gear case skid plate (see Front Final
Gear Case Oil Level Inspection in the Final Drive chapter).
Brakes
Brake Fluid Level Inspection
•
With the vehicle on level ground, check that the fluid level in the reservoir is between the upper (MAX) and lower
(MIN) level lines.
○
Look the fluid level through the hole [A] in the control panel.
If the fluid level is lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line.
WARNING
Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified.
•
Tilt up the front cargo hood.
•
Remove:
Rubber Cap [A]
Periodic Maintenance Procedures
•
Fill the reservoir to the upper level line [A].
Upper Level Line (MAX)
Lower Level Line (MIN) [B]
Hole [C] of Front Cargo Compartment
•
Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.
WARNING
Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake pedal has a soft or "spongy" feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.
PERIODIC MAINTENANCE 2-33
•
Brake Fluid Change
Tilt up the front cargo hood.
•
Level the brake fluid reservoir [A].
NOTE
○
The fluid level must be checked several times during the fluid changing and replenished as necessary. If the fluid in the reservoir runs completely out any time during fluid changing, air bleeding must be done since air will have entered the line.
•
Remove the wheel for extra clearance (see Wheel Removal in the Wheels/Tires chapter).
•
Remove the reservoir cap.
•
Remove the rubber cap from the bleed valve on the wheel cylinder.
•
Connect a clear plastic hose [A] to the bleed valve at the wheel cylinder, running the other end of the hose into a container.
Left Front Brake Panel [B]
NOTE
○
Start with the rear left or right wheel and finish with the front left or right wheel.
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
•
Fill the reservoir with new brake fluid.
Temporarily install the reservoir cap.
•
Change the brake fluid as follows.
1. Open bleed valve.
2. Pump brake pedal and hold it.
3. Close bleed valve.
4. Release brake pedal.
•
Tighten:
Torque - Bleed Valves: 5.4 N·m (0.55 kgf·m, 48 in·lb)
•
Repeat the previous step for each wheel.
•
When brake fluid changing is finished, add the fluid to the upper level in the reservoir.
•
After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the brake lines (see Brake
Line Air Bleeding in the Brakes chapter).
WARNING
Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake pedal has a soft or "spongy" feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.
•
Install the removed parts (see appropriate chapters).
Brake Pedal Play Inspection
•
Check the brake pedal play [A].
Brake Pedal Play
Standard: 2
∼ 10 mm (0.08 ∼ 0.39 in.)
If the play is not correct, adjust it.
•
Remove the front cargo compartment (see Front Cargo
Compartment Removal in the Frame chapter).
•
Loosen the locknut [A] and turn the push rod [B] to obtain the correct amount of free play.
•
Tighten:
Torque - Push Rod Locknut: 17.2 N·m (1.8 kgf·m, 13 ft·lb)
•
Check the brake for good braking power and no brake drag.
WARNING
Insufficient free play can cause brake heating and drag, resulting in skidding and loss of control which could cause an accident resulting in serious injury or death. Be sure the brake free play is adjusted to the specification.
Periodic Maintenance Procedures
Brake Master Cylinder Cup and Dust Seal
Replacement
•
Remove the master cylinder (see Master Cylinder Removal in the Brakes chapter).
•
Remove the piston stop bolt [G].
•
Remove the dust seal [A] and then the retainer [B] with the circlip pliers.
Special Tool - Inside Circlip Pliers: 57001-143
○
Remove the piston assembly (two pistons) by lightly tap the master cylinder on a wooden block.
Pistons [C]
Springs [D]
Secondary Cups [E]
Primary Cups [F]
Master Cylinder [H]
○
Be careful of the secondary cup direction [I].
PERIODIC MAINTENANCE 2-35
•
Assemble the master cylinder.
○
Clean all the parts including the master cylinder with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder.
NOTICE
Use only brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake.
○
Push the piston assembly in all the way with a screwdriver and install the piston stop bolt. Use a new aluminum washer.
○
Tighten:
Torque - Piston Stop Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Reservoir Clamp Bolt: 6.1 N·m (0.62 kgf·m, 54 in·lb)
•
Install the master cylinder (see Master Cylinder Installation in the Brakes chapter).
Brake Hose and Pipe Inspection
•
The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.
Replace it if any cracks [B] or bulges [C] are noticed.
•
The metal pipe will rust if the plating is damaged.
Replace the pipe if it is rusted, cracked (especially check the fittings), or if the plating is badly scratched (see Brake
Hose and Pipe Replacement).
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Brake Hose and Pipe Replacement
To remove the brake pipe [A], unscrew the nipple [B].
•
To remove the hoses [C], remove the banjo bolts [D] and/or pull out the retainers.
○
The front cargo compartment inside is shown.
•
Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Use a new copper washer for each side of the hose fittings at the master cylinder.
•
Apply brake fluid to the threads of the nipple [B] of the brake pipe [A].
•
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
•
Check that the brake line has proper fluid pressure and no fluid leakage.
○
The left front brake drum is shown.
○
The left front knuckle is shown.
Brake Pipe [A]
Nipple [B]
Brake Hose [C]
Retainer [D]
○
The rear-middle of the vehicle is shown with the cargo bed tilted up.
Brake Hose and Pipes [A]
Nipples [B]
Periodic Maintenance Procedures
○
The middle-left of the vehicle is shown with the cargo bed tilted up.
Brake Pipe [A]
Nipple [B]
Brake Hose [C]
Retainer [D]
Torque Converter Outer Cover [E]
Front [F]
PERIODIC MAINTENANCE 2-37
○
The rear-left brake line is shown.
Brake Pipe [A]
Nipple [B]
Brake Hose [C]
Retainer [D]
Front [E]
Brake Wear Inspection
•
Remove the brake drum (see Brake Drum Removal in the
Brakes chapter).
•
Measure the inside diameter [A] of the drum at several points.
If any measurement is greater than the service limit, replace the drum.
If the drum is worn unevenly or scored, lightly turn the drum on a brake drum lathe or replace it. Do not turn the drum beyond the service limit.
Brake Drum Inside Diameter
Standard: 180.000
∼ 180.160 mm
(7.0866
∼ 7.0929 in.)
Service Limit: 180.75 mm (7.116 in.)
•
Remove the brake drum for brake shoe inspection (see
Brake Drum Removal in the Brakes chapter).
•
Measure the lining thickness at several points.
Brake Shoe Lining Thickness
Standard: 4.5 mm (0.18 in.)
Service Limit: 1.0 mm (0.04 in.)
If any measurement is less than the service limit, replace both shoes as a set.
If the lining thickness is greater than the service limit, do the following before installing the shoes.
•
File or sand down any high spots on the surface on the lining.
•
Use a wire brush to remove any foreign particles from the lining.
•
Wash off any oil or grease with an oilless solvent.
NOTICE
Do not use a solvent which will leave an oily residue. The shoes will have to be replaced.
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Wheel Cylinder Assembly Replacement
(Front Brake Panel)
•
Remove the brake drum (see Brake Drum Removal in the
Brakes chapter).
○
The left front brake panel is shown.
•
Remove the brake shoe springs [A] and brake shoes [B] individually.
○
Push the shoe hold-down springs [C] and twist the pins
[D] to remove the shoes.
NOTE
○
Wrap the brake shoes with a clean cloth to protect the linings from grease or dirt.
•
Remove the brake pipe nipple [A] and plug the nipple.
○
Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Unscrew the mounting bolts [B] and take off [C] the front brake wheel cylinder.
(Rear Brake Panel)
•
Remove the brake shoes [A] in the same way as in the front brake panel.
Rear Brake Wheel Cylinder [B]
•
(Rear Brake Panel)
Remove the brake pipe nipple [A] and plug the nipple.
•
Unscrew the mounting nuts [B] and take off [C] the rear brake wheel cylinder.
Front [D]
Periodic Maintenance Procedures
•
Replace the rear wheel cylinder with a new one.
•
Set the brake shoe clearance adjuster so that the drum can be reinstalled on the panel assembly.
(Front Brake Panel)
○
Turn [A] either end of the cylinder fully while holding the other end [B]. Both ends are put into the cylinder.
PERIODIC MAINTENANCE 2-39
(Rear Brake Panel)
○
Push the ratchet [A] forwards and in to reset the shoe clearance adjuster from the protruding position to its original position. The stop [B] sets the position.
Left Parking Brake Lever Linkage [A] of Rear Brake
Ratchet [B]
Protruding Position [C]
Shoe Clearance Adjuster [E]
Front [F]
Left Parking Brake Lever Linkage [A] of Rear Brake
Ratchet [B]
Original Position [D]
Shoe Clearance Adjuster [E]
Front [F]
•
Apply brake fluid to the threads of the brake pipe nipple and tighten it.
Torque - Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
Front Wheel Cylinder Mounting Bolts: 10.3 N·m
(1.1 kgf·m, 91 in·lb)
Rear Wheel Cylinder Mounting Nuts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Apply grease to the following portions (front and rear brake panels).
Brake Panel and Brake Shoe Contact Points [A]
Wheel Cylinder Piston Ends [B]
Brake Shoe Anchor Ends [C]
○
The left front brake is shown.
(Rear Brake Panel)
•
Grease the shoe clearance adjuster pivots [A].
(Rear Brake Panel)
•
Pack the gaps [A] with a little grease.
(Front and Rear Brake Panels)
•
Bleed the brake line after drum installation (see Brake
Line Air Bleeding in the Brakes chapter).
•
Be sure to check the brake system for good braking power, no brake drag and no fluid leakage.
WARNING
After servicing, it takes several applications of the brake pedal before the brake shoes contact the drum, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum.
•
Inspect the parking brake lever (see Parking Brake Lever
Inspection).
Parking Brake Lever Inspection
•
Check parking brake lever travel [A] by feeling clicks.
○
Pull the parking brake lever [B] upward slowly all the way.
Count the number of notches (clicks) during lever travel.
○
The vehicle should not roll while parked.
Parking Brake Lever Travel
Standard: 8
∼ 12 notches (clicks) at 200 N (20 kgf, 44
lb)
•
Release the parking brake and return the lever to its rest position.
Periodic Maintenance Procedures
•
If the lever travel is not correct, adjust it.
Pull up the rubber boot [A].
•
Loosen the locknut [B] and turn the adjusting nut [C] to obtain the correct amount of lever travel.
•
Tighten the locknut.
•
Check the parking brake for good braking power and when released, no brake drag.
WARNING
Insufficient free play can cause brake heating and drag, resulting in skidding and loss of control which could cause an accident resulting in serious injury or death. Be sure the brake free play is adjusted to the specification.
PERIODIC MAINTENANCE 2-41
NOTE
○
If the parking brake lever travel cannot be adjusted with the adjusting nut at the lever, remove the cover [A] and use the adjusters [B] behind the parking brake lever and adjusters [C] near the rear wheels. Be sure to adjust both the left and right cables evenly, and then securely tighten the adjuster mounting nuts [D].
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering
•
Steering Inspection
Check steering wheel free play [A].
○
Set the front wheels straight ahead. Gently turn [B] the steering wheel left and right. The steering wheel free play is the amount of travel in the steering wheel, before the front wheels begin to turn.
Steering Wheel Free Play
Standard: 0
∼ 20 mm (0 ∼ 0.79 in.)
If steering wheel free play is not correct, inspect the following.
Steering Wheel Mounting Nut (see Steering Wheel Centering in the Steering chapter)
Universal Joint Clamp Bolts (see Exploded View in the
Steering chapter)
EPS Unit Mounting Bolts (see EPS Unit Installation in the Steering chapter)
Steering Gear Assembly Bracket Bolts (see Steering
Gear Assembly Installation in the Steering chapter)
Steering Gear Assembly Mounting Rubber Dampers
Tie-Rod End Nuts (see Steering Gear Assembly Installation in the Steering chapter)
Steering Gear Preload Adjustment (see Steering Gear
Preload Adjustment in the Steering chapter)
If the inspections above are good but the free play is out of the specified, the steering gear assembly is damaged and should be replaced as a unit.
Steering Joint Dust Boot Inspection
•
Visually inspect the dust boots [A] at both the ends of the steering gear assembly.
Front [B]
If there is any signs of deterioration, cracks, or damage, replace the steering gear assembly together with these boots.
Periodic Maintenance Procedures
Frame
Seat Belt Inspection
•
Check the belts [A] for damage or tear.
If necessary, replace the belt with a new one.
•
Check the tightness torque of the seat belt mounting bolts
[B].
Torque - Seat Belt Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Seat Belt Buckle Mounting Bolts [C]: 34 N·m (3.5
kgf·m, 25 ft·lb)
PERIODIC MAINTENANCE 2-43
•
Check the operation of the buckle [A].
○
Set the plate [B] in the buckle, and confirm the plate does not come off when pulling it.
○
Set the plate in the buckle, and confirm the plate comes off when the buckle button [C] is pushed.
If operation is not correct, visually inspect the plate.
If the plate is damaged, replace the plate assembly with a new one.
If the plate is not damaged, replace the buckle assembly.
Electrical System
Electrolyte Level Inspection (Conventional Type
Battery)
WARNING
Electrolyte contains sulfuric acid which is harmful to skin, eyes, and clothing.
Wear eye protection and rubber gloves.
If spillage occurs on body or clothing, rinse at once with water for at least 15 minutes.
•
Remove the filler caps [A] on the battery.
○
Lift the side of the cap [B] opposite the terminals, and then lift the side of the cap nearest the terminals.
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
The electrolyte level should be between the upper and lower levels.
○
Upper level is bottom [A] of the split ring [B].
○
Lower level is top of the plates [C].
If the level of electrolyte in any cell is below the lower level, add only distilled water to the upper level of the cell.
NOTICE
Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.
Do not fill into the split [D].
Do not overfill.
Electrolyte Specific Gravity Inspection
(Conventional Type Battery)
WARNING
Electrolyte contains sulfuric acid which is harmful to skin, eyes, and clothing.
Wear eye protection and rubber gloves.
If spillage occurs on body or clothing, rinse at once with water for at least 15 minutes.
•
Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer.
○
Read the level [A] of the electrolyte on the floating scale
[B].
Specific Gravity
Standard: 1.265 at 20°C (68°F)
If the specific gravity is below 1.20 (charge 70%), the battery needs to be charged.
NOTE
○
The specific gravity of the electrolyte varies with changes in temperature, so the specific gravity reading must be corrected for the temperature of the electrolyte.
○
Celsius: Add 0.007 points to reading for each 10°C
(50°F) above 20°C (68°F) or subtract 0.007 points for each 10°C (50°F) below 20°C (68°F)
○
Fahrenheit: Add 0.004 points to reading for each –12°C
(10°F) above 20°C (68°F) or subtract 0.004 points for each –12°C (10°F) below 20°C (68°F)
If the specific gravity of any of the cells is more than 0.050
away from any other reading, the battery will probably not accept a charge. It is generally best to replace a battery in this condition.
If the specific gravity of all the cells is 1.265 or more, the battery is fully charged.
Periodic Maintenance Procedures
Charging Condition Inspection (Conventional
Type Battery)
○
Battery charging condition can be checked by measuring battery terminal voltage.
•
Disconnect the battery terminal cables.
NOTICE
Be sure to disconnect the negative terminal cables first.
•
Measure the battery terminal voltage.
NOTE
○
Measure with a digital voltmeter [A] which can be read to 0.1 volt.
If the reading is below the specified, refreshing charge is required.
Battery Terminal Voltage
Standard: 12.6 V or more
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Refresh charge is required [C]
Note [D]
Good [E]
Brake Light Switch Inspection
•
Check the operation of the brake light switch by depressing the brake pedal. The brake light should go on after 10 mm (0.39 in.) of pedal travel [A].
PERIODIC MAINTENANCE 2-45
If it does not, adjust the brake light switch [A] up or down.
To change the switch position, turn the adjusting nut [B].
Brake Light Switch Timing
Standard: ON after 10 mm (0.39 in.) of pedal travel
NOTICE
To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
General Lubrication
•
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
•
Lubricate the points listed below with indicated lubricant.
NOTE
○
Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.
Pivots and Points: Lubricate with Grease.
2WD/4WD Shift Lever Pivot
Brake Pedal Pivot
Cargo Bed Mounting Pins
Differential Shift Lever Pivot
Propeller Shaft Bearing [A] (under Fuel Tank)
Seat Brackets
Throttle Pedal Pivot
Transmission Shift Lever Pivot
○
Grease the propeller shaft bearing using the grease nipple [B].
Cables: Lubricate with Grease.
2WD/4WD Shift Cable
Differential Shift Cable
Parking Brake Cables
Throttle Cable
Cables: Lubricate with Rust Inhibitor.
2WD/4WD Shift Cable
Differential Shift Cable
Throttle Cable
Periodic Maintenance Procedures
•
With the cable disconnect at both ends, the cable should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
PERIODIC MAINTENANCE 2-47
Bolts, Nuts and Fasteners Tightness Inspection
•
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition.
NOTE
○
Check the engine fastener tightness when the engine is cold (at room temperature).
If there are loose fasteners, first loosen by 1/2 turn, then retorque them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the basic torque table.
Bolt, Nut, and Fasteners to be checked
Engine
Engine Mounting Bolts
Exhaust Pipe and Muffler Joint Bolts
Exhaust Pipe Holder Nuts
Fuel Tank Bolt and Nut
Muffler Mounting Bolts
Throttle Pedal Pivot Cotter Pin
Transmission/Final Drive
2WD/4WD Shift Lever Pivot Snap Pin
2WD/4WD Shift Shaft Lever Mounting Nut
Axle Nuts and Cotter Pins
Differential Shift Cable Upper End Snap Pin
Differential Shift Lever Pivot Snap Pin
Differential Shift Shaft Lever Mounting Nut
Hi/Low Shift Cable Upper End Snap Pin
Hi/Low Shift Lever Pivot Snap Pin
Hi/Low Shift Shaft Lever Mounting Nut
Propeller Shaft Bearing Housing Nuts
Shift Shaft Lever Clamp Bolts
Transmission Shift Cable Upper End Snap Pin
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheels
Wheel Nuts
Brakes
Brake Pedal Pivot Shaft Cotter Pin
Master Cylinder Mounting Bolts
Master Cylinder Push Rod Joint Cotter Pin
Parking Brake Cable Lower End Joint Cotter Pins
Parking Brake Lever Assembly Mounting Bolts
Suspension
Front Suspension Arm Pivot Bolts
Leaf Spring Mounting Nuts
Rear Shock Absorber Mounting Nuts
Strut Clamp Nuts and Cotter Pins
Strut Mounting Locknuts
Steering
Front Suspension Arm Joint Nuts and Cotter Pins
Steering Shaft Mounting Bolts and Nuts
Steering Wheel Mounting Nut
Tie-Rod End Locknuts
Tie-Rod End Nuts and Cotter Pins
Universal Joint Clamp Bolts
Frame
Battery Holder Mounting Nuts
Cargo Bed Hook Mounting Bolts
Cargo Bed Mounting Pin Snap Pins
Front and Rear Bar Mounting Bolts and Nuts
Front and Rear Seat Back Mounting Nuts
Front and Rear Seat Belt Mounting Bolts
Front and Rear Seat Belt Backle Mounting Bolts
Front Final Gear Case Skid Plate Mounting Bolts
Front Guard Nuts
Rear End Subframe Mounting Nuts
Seat Bracket Nuts
FUEL SYSTEM 3-1
Fuel System
Table of Contents
Fuel Level Gauge Removal (KAF950G9
∼ GC/HA)..........................................................
Fuel Level Gauge Installation (KAF950G9
∼ GC/HA).......................................................
Fuel Level Gauge Check (KAF950G9
∼ GC/HA)..............................................................
3
3-2 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-3
Exploded View
No.
Fastener
1 Air Cleaner Housing Mounting Bolts
2 Air Duct Mounting Bolt
N·m
20
5.0
3. Approximately 60°
4. Horizontal Line
5. Install the duct so that the long side faces frame.
6. Position the outlet boot downward.
7. KAF950G9, GA/HA
G: Apply grease.
R: Replacement Parts
Torque kgf·m
2.0
0.51
ft·lb
15
44 in·lb
Remarks
3-4 FUEL SYSTEM
Exploded View
KAF950G9
∼ GC/HA
FUEL SYSTEM 3-5
Exploded View
No.
1
11
Air Vent Plug
Fastener
2 Distributor Head Bolt
3 Fuel Filter Mounting Bolts
4 Fuel Injection Nozzles
5 Fuel Injection Pipe Clamp Bolts
6 Fuel Injection Pipe Mounting Nuts
7 Fuel Injection Pump Bracket Bolts
8 Fuel Injection Pump Gear Nut
9 Fuel Injection Pump Mounting Nuts
10 Idle Adjusting Screw Locknut
Linkage Pipe Nuts
12 Maximum Speed Set Screw Locknut
N·m
5.0
17
20
59
7.4
25
20
64
20
6.9
27
6.9
13. Air Vent Hose
14. Check Valve
15. Fuel Output Hose (from Fuel Filter to Fuel Injection Pump)
16. Fuel Output Hose (from Fuel Tank to Fuel Filter)
17. Fuel Return Hose (from Fuel Injection Pump to Fuel Tank)
18. KAF950G9, GA/HA
AD: Apply adhesive.
G: Apply grease.
R: Replacement Parts
Torque kgf·m
0.51
1.7
2.0
6.0
0.75
2.5
2.0
6.5
2.0
0.70
2.8
0.70
ft·lb
44 in·lb
13
15
44
65 in·lb
18
15
47
15
61 in·lb
20
61 in·lb
Remarks
3-6 FUEL SYSTEM
Exploded View
KAF950GD
FUEL SYSTEM 3-7
Exploded View
No.
Fastener
1 Air Vent Plug
2 Distributor Head Bolt
3 Fuel Filter Mounting Bolts
4 Fuel Injection Nozzles
5 Fuel Injection Pipe Clamp Bolts
6 Fuel Injection Pipe Mounting Nuts
7 Fuel Injection Pump Bracket Bolts
8 Fuel Injection Pump Gear Nut
9 Fuel Injection Pump Mounting Nuts
10 Idle Adjusting Screw Locknut
11 Linkage Pipe Nuts
12 Maximum Speed Set Screw Locknut
13 Fuel Level Gauge Mounting Bolts
N·m
5.0
17
20
59
7.4
25
20
64
20
6.9
27
6.9
4.0
14. Air Vent Hose
15. Check Valve
16. Fuel Output Hose (from Fuel Filter to Fuel Injection Pump)
17. Fuel Output Hose (from Fuel Tank to Fuel Filter)
18. Fuel Return Hose (from Fuel Injection Pump to Fuel Tank)
AD: Apply adhesive.
G: Apply grease.
R: Replacement Parts
2.5
2.0
6.5
2.0
0.70
2.8
0.70
0.41
Torque kgf·m
0.51
1.7
2.0
6.0
0.75
ft·lb
44 in·lb
13
15
44
65 in·lb
18
15
47
15
61 in·lb
20
61 in·lb
35 in·lb
Remarks
3-8 FUEL SYSTEM
Specifications
Item
Throttle Pedal and Cable
Throttle Pedal Play
Fuel Injection Nozzle
Fuel Injection Nozzle Injection
Pressure:
Marking of Injection Nozzle:
Red or Green
None
Fuel Injection Pump
Idle Speed
Maximum Engine Speed (No Load)
Injection Timing (Plunger Stroke):
Marking of Injection Nozzle:
Red or Green
None
Injection Nozzle Mark Position [A]
Standard
5
∼ 10 mm (0.20 ∼ 0.39 in.)
13 239
∼ 14 220 kPa (135 ∼ 145 kgf/cm², 1 920
∼ 2 062 psi)
14 465
∼ 14 955 kPa (147.5 ∼ 152.5
kgf/cm², 2 098
∼ 2 169 psi)
850
∼ 950 r/min (rpm)
3 800
∼ 3 900 r/min (rpm)
0.81 ±0.03 mm (0.0319 ±0.0012 in.)
0.81 ±0.02 mm (0.0319 ±0.0008 in.)
Service Limit
– – –
– – –
– – –
– – –
– – –
– – –
– – –
Special Tool
Dial Gauge Adapter:
57001-1430
FUEL SYSTEM 3-9
3-10 FUEL SYSTEM
Throttle Pedal and Cable
Throttle Pedal Play Inspection
•
Refer to the Throttle Pedal Play Inspection in the Periodic
Maintenance chapter.
Throttle Pedal Play Adjustment
•
Refer to the Throttle Pedal Play Adjustment in the Periodic
Maintenance chapter.
•
Full Throttle Pedal Position Adjustment
•
Loosen the locknut [A].
Screw in the throttle pedal stop bolt [B].
•
Tilt up the cargo bed.
•
Remove:
Injection Pump Cover Bolts [A] and Collars
Injection Pump Cover [B]
•
Reinstall the collars [A] and tighten the pump cover bolts
[B] together with the bracket [C] temporary.
•
Depress the throttle pedal until the speed control lever [A] on the injection pump is in the fully opened position, and hold it there.
•
Turn the throttle pedal stop bolt until the bolt head lightly touches the bottom of the throttle pedal.
•
Tighten the locknut securely.
Throttle Pedal and Cable
Throttle Cable Installation
•
Run the throttle cable correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
•
Adjust the throttle pedal play adjustment (see Throttle
Pedal Play Adjustment in the Periodic Maintenance chapter).
WARNING
Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. Follow the service manual to be make sure to correct any of these conditions.
Throttle Cable Lubrication
Whenever the throttle cable is removed, lubricate the cable as follows.
•
Apply a thin coating of grease to the cable upper and lower ends.
•
Lubricate the cable with a penetrating rust inhibitor through a pressure cable luber.
Throttle Cable Inspection
•
With the throttle cable disconnected at both ends, the cable should move freely [A] within the cable housing.
If the cable does not move freely after lubricating, if the cable is frayed [B], or if the housing is kinked [C], replace the cable.
FUEL SYSTEM 3-11
3-12 FUEL SYSTEM
Fuel Injection Nozzle
•
Fuel Injection Nozzle Removal
Tilt up the cargo bed.
•
Remove:
Fuel Injection Pipes (see Fuel Injection Pipe Removal)
Fuel Return Hose [A]
Linkage Pipe Nuts [B]
Linkage Pipe [C]
•
Remove:
Washer [A]
Fuel Injection Nozzle [B] and Gasket
NOTICE
Handle the fuel injection nozzles with extreme care.
Do not drop the nozzles.
•
Fuel Injection Nozzle Installation
Replace the gasket [A] with a new one.
•
Install the fuel injection nozzle [B].
Torque - Fuel Injection Nozzles: 59 N·m (6.0 kgf·m, 44 ft·lb)
•
Replace the washer [C] with a new one.
•
Install:
Linkage Pipe [D]
Linkage Pipe Nuts [E]
Torque - Linkage Pipe Nuts: 27 N·m (2.8 kgf·m, 20 ft·lb)
•
Install:
Fuel Return Hose
Fuel Injection Pipes (see Fuel Injection Pipe Installation)
Fuel Injection Nozzle Inspection
WARNING
Fuel is released from the injection nozzle at high pressure and is highly flammable. Keep hands, fingers and other body parts at least 12 inches from the nozzle during testing. 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.
NOTE
○
Refer to the Fuel Injection Pump Inspection and Repair for nozzle repair information.
Fuel Injection Nozzle
•
Injection Pressure Check
Install the fuel injection nozzle on a nozzle tester.
•
Quickly move the tester lever up and down so that the injection nozzle sprays two to three times.
○
This step blows off any carbon deposits on the injection nozzle port.
•
Move the lever very slowly, gradually raising the pressure.
•
Measure the maximum pressure just as the pointer of the pressure gauge drops suddenly.
Fuel Injection Nozzle Injection Pressure
Marking of Injection Nozzle:
Red or Green: 13 239
∼ 14 220 kPa (135 ∼ 145
kgf/cm², 1 920
∼ 2 062 psi)
None: 14 465
∼ 14 955 kPa (147.5 ∼ 152.5
kgf/cm², 2 098
∼ 2 169 psi)
If the measured pressure does not comply with the specification, replace the injection nozzle.
Leakage Check
(When there is a mark (green or red) on the nozzle.)
•
Slowly depress the tester lever, until the pressure reaches about 11 768 kPa (120 kgf/cm², 1 706 psi.)
(When there is no mark on the nozzle.)
•
Slowly depress the tester lever, until the pressure reaches about 12 749 kPa (130 kgf/cm², 1 849 psi.)
Checking for “Buzzing” and Spray Pattern
•
Operate the tester lever at a rate of 30 to 60 strokes per minute in the case of a new nozzle; 15 to 60 strokes per minute in the case of a used nozzle.
•
Make sure that “buzzing” occurs during these strokes.
NOTE
○
When this “buzzing” occurs, you can feel a pulsation transmitted to your hand through the nozzle tester handle while the nozzle injection is taking place.
○
When the pressurized fuel from the injection pump is injected, this injection is accompanied by rapid, recurring pressure variations during the time from the start to the finish of the injection. These pulsing pressure variations are felt as “buzzing”.
○
These pulsations of the fuel are affected mainly by the movement of the nozzle needle and good or bad conditions of the valve seat section.
○
Generally, a nozzle that “buzzes” is good, because a spray condition where intermittent pulsations are generated assures good “cut-off” of the fuel supply.
FUEL SYSTEM 3-13
3-14 FUEL SYSTEM
Fuel Injection Nozzle
•
Ensure that the fuel spray forms a cone shape while the
“buzzing” is occurring, and that the center of the cone is aligned with the center line of the nozzle.
•
Ensure that the nozzle does not drip.
Fuel Injection Pump
Idle Speed Inspection
•
Refer to the Idle Speed Inspection in the Periodic Maintenance chapter.
Idle Speed Adjustment
•
Refer to the Idle Speed Adjustment in the Periodic Maintenance chapter.
Maximum Engine Speed Inspection
•
Check the full throttle pedal position (see Full Throttle
Pedal Position Adjustment).
•
Set the parking brake.
•
Be sure the transmission is in neutral.
•
Start the engine and warm it up thoroughly.
•
Tilt up the cargo bed.
•
Check the maximum engine speed with a suitable tachometer.
Maximum Engine Speed (No Load)
Standard: 3 800
∼ 3 900 r/min (rpm)
If the maximum engine speed is not in the specified range, adjust it.
•
•
Maximum Engine Speed Adjustment
Set the parking brake.
•
Be sure the transmission is in neutral.
•
Tilt up the cargo bed.
Remove the fuel injection pump cover (see Full Throttle
Pedal Position Adjustment).
•
Cut and remove the wire [A] on the maximum speed set screw [B].
•
Start the engine and warm it up thoroughly.
•
Loosen the locknut [C].
•
Turn the maximum speed set screw until the maximum engine speed is correct.
•
Tighten:
Torque - Maximum Speed Set Screw Locknut: 6.9 N·m (0.70
kgf·m, 61 in·lb)
•
Lock the maximum speed set screw with a wire or paint on the locknut and pump housing.
Fuel Injection Pipe 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.
NOTICE
Take care to prevent any dirt from entering injection nozzle holes or delivery valve ports when fuel delivery lines are removed.
FUEL SYSTEM 3-15
3-16 FUEL SYSTEM
Fuel Injection Pump
•
Cut the bands [A].
•
Remove:
Air Duct Mounting Screw [B]
Air Duct [C]
•
Remove the air duct [A].
•
Remove:
Fuel Injection Pipe Clamp Bolts [A]
Fuel Injection Pipe Clamps [B]
•
Loosen the fuel injection pipe upper nuts [C].
•
Remove:
Fuel Injection Pipe No. 3 Lower Nut [A] and Upper Nut
Fuel Injection Pipe No. 1 Lower Nut [B] and Upper Nut
Fuel Injection Pipe No. 2 Lower Nut [C] and Upper Nut
•
Fuel Injection Pipe Installation
Install the fuel injection pipes using the following steps.
○
First, install the No. 2 injection pipe [A].
○
Secondly, install the No. 1 injection pipe.
○
Finally, install the No. 3 injection pipe.
NOTE
○
Tighten the upper and lower nuts temporarily and then tighten them to the specified torque.
•
Tighten:
Torque - Fuel Injection Pipe Mounting Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Fuel Injection Pipe Clamp Bolts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
Fuel Injection Pump
Fuel Injection Pump Removal
•
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Fuel Injection Pump Drive Gear (see Timing Gear Case
Removal in the Crankshaft/Crankcase chapter)
Fuel Injection Pipes (see Fuel Injection Pipe Removal)
Fuel Return Hose [A]
Fuel Injection Pump Bracket Bolts [B]
Fuel Injection Pump Bracket [C]
•
Remove:
Fuel Injection Pump Mounting Nuts [A]
Fuel Injection Pump [B]
FUEL SYSTEM 3-17
•
Fuel Injection Pump Installation
•
Replace the O-ring [A] with a new one.
Apply grease to the new O-ring.
•
Install the fuel injection pump temporary.
○
Align the timing marks [A] on the injection pump and timing gear case.
○
Tighten the mounting nuts with fingers.
3-18 FUEL SYSTEM
Fuel Injection Pump
•
Install:
Fuel Injection Pump Drive Gear, Timing Gear Case
Cover and Crankshaft Pulley (see Timing Gear Case
Installation in the Crankshaft/Crankcase chapter)
•
Adjust the fuel injection pump timing (see Fuel Injection
Pump Timing Inspection).
•
Tighten:
Torque - Fuel Injection Pipe Mounting Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Fuel Injection Pipe Clamp Bolts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
•
Adjust:
Maximum Engine Speed (New Injection Pump) (see
Maximum Engine Speed Adjustment)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
Fuel Injection Pump Timing Inspection
•
Remove:
Fan Belt Cover (see Cooling Fan Belt Inspection in the
Periodic Maintenance chapter)
Fuel Injection Pipes (see Fuel Injection Pipe Removal)
Cylinder Head Cover (see Rocker Arm Components Removal in the Engine Top End chapter)
Oil Level Gauge Pipe (see End Plate Removal in the
Crankshaft/Crankcase chapter)
Torque Converter Case (see Torque Converter Case Removal in the Converter System chapter)
•
Turn the crankshaft pulley [A] clockwise, and position the crankshaft at #1 piston TDC on the compression stroke.
○
Align the timing mark [B] on the crankshaft pulley and reference point [C] on the timing case cover.
○
If the inlet and exhaust valves for #1 cylinder have no clearance, turn the crankshaft pulley one revolution.
•
Remove the distributor bolt [A].
Fuel Injection Pump
•
Install the dial gauge adapter [A] and dial gauge [B].
Special Tool - Dial Gauge Adapter: 57001-1430
FUEL SYSTEM 3-19
•
Slowly turn the crankshaft pulley counterclockwise about
30° until the dial gauge needle stops. Pump plunger lift is zero at this point.
•
Set the dial gauge to the “0” position.
•
Slowly turn the crankshaft pulley clockwise, stopping at
#1 piston TDC on the compression stroke.
NOTE
○
Do not turn the crankshaft pulley past TDC. If the crankshaft pulley is turned past TDC, turn the crankshaft back to “0” on the dial gauge and repeat the procedure.
•
Note dial gauge reading.
Injection Timing (Plunger Stroke)
Marking of Injection Nozzle:
Red or Green: 0.81 ±0.03 mm (0.0319 ±0.0012 in.)
None: 0.81 ±0.02 mm (0.0319 ±0.0008 in.)
If the gauge reading is within the specification, the injection pump is properly timed.
If the gauge reading is not within the specification, adjust the injection pump timing (see Fuel Injection Pump Timing
Adjustment).
Fuel Injection Pump Timing Adjustment
•
Inspect the fuel injection pump timing.
NOTE
○
Do not turn the crankshaft pulley past TDC. If the crankshaft pulley is turned past TDC, turn the crankshaft back to “0” and repeat the procedure.
3-20 FUEL SYSTEM
Fuel Injection Pump
•
Loosen the fuel injection pump mounting nuts [A].
•
Loosen the fuel injection pump bracket bolt [A].
•
While observing the dial gauge, slowly rotate the fuel injection pump away from the cylinder head until gauge reads 0.81 ±0.03 mm (0.0319 ±0.0012 in.).
•
Hold the fuel injection pump in this position and tighten the fuel injection pump mounting nuts.
NOTE
○
Do not rotate the pump past the specification. If the pump is rotated past the specification, rotate the pump back toward the cylinder head and repeat the procedure.
•
Tighten:
Torque - Fuel Injection Pump Mounting Nuts: 20 N·m (2.0
kgf·m, 15 ft·lb)
Fuel Injection Pump Bracket Bolts: 20 N·m (2.0
kgf·m, 15 ft·lb)
•
To verify that the timing is correct, turn the crankshaft pulley counterclockwise until the dial indicator reads “0”.
•
Then turn the crankshaft pulley clockwise until the timing mark on the crankshaft pulley aligns with reference point on the timing case cover.
•
The indicator should be within the specification.
Injection Timing (Plunger Stroke)
Marking of Injection Nozzle:
Red or Green: 0.81 ±0.03 mm (0.0319 ±0.0012 in.)
None:
0.81 ±0.02 mm (0.0319 ±0.0008 in.)
If the indicator reading is not within the specification, re-
• peat the procedure.
Remove the dial gauge adapter and dial gauge.
•
Install the distributor head bolt and washer.
•
Tighten:
Torque - Distributor Head Bolt: 17 N·m (1.7 kgf·m, 13 ft·lb)
Fuel Injection Pump
Fuel Injection Pump Inspection and Repair
NOTE
○
Do not disassemble the fuel injection pump and injection nozzles. The pump and nozzles are produced in highly automated modern production facilities. They cannot be assembled by hand in the field.
•
Refer to the troubleshooting section to check of the pump.
If the pump and nozzle are malfunction, replace them, or consult a reliable repair shop (ex. Denso Service Station).
FUEL SYSTEM 3-21
3-22 FUEL SYSTEM
Fuel Injection Pump Troubleshooting
Fuel Injection Pump Troubleshooting
FUEL SYSTEM 3-23
3-24 FUEL SYSTEM
Fuel Injection Pump Troubleshooting
Fuel Injection Pump Troubleshooting
FUEL SYSTEM 3-25
3-26 FUEL SYSTEM
Fuel Injection Pump Troubleshooting
Fuel Injection Pump Troubleshooting
FUEL SYSTEM 3-27
3-28 FUEL SYSTEM
Fuel Injection Pump Troubleshooting
Air Cleaner
A clogged engine air cleaner restricts the engine’s air inlet, increasing fuel consumption, reduction engine power.
NOTICE
A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possible engine damage.
The engine air filter restriction gauge [A] shows whether the air cleaner is clogged. Whenever the red band shows in the gauge window [B], the air cleaner element should be cleaned.
•
Air Cleaner Element Cleaning
•
Unlock the clamps [A].
Remove the air cleaner cover [B].
FUEL SYSTEM 3-29
•
Remove the element [A].
•
Clean the element by tapping gently with the handle end of a screwdriver.
If the element is very dirty or damaged, replace the element.
•
Carefully clean out the air cleaner cover.
•
Install the cover and lock the clamps.
○
Face the TOP mark [A] upward.
3-30 FUEL SYSTEM
Air Cleaner
•
Reset the air filter restriction gauge [A].
○
After servicing the air cleaner element, the restriction gauge should be reset by pushing the button [B] at the end of the gauge.
•
Air Cleaner Housing Removal
Tilt up the seat.
•
Remove:
Air Ducts [A]
Air Cleaner Housing Mounting Bolts [B]
Air Cleaner Housing [C]
Air Cleaner Housing Installation
•
Apply sealant to the area [A] shown in the figure.
Sealant - General Electric: RTV100 (Black)
○
Do not apply sealant to the inside [C] of the duct.
•
Install the air ducts [B] and tighten the clamp screws.
•
Install the air cleaner housing [A] as shown in the figure.
Approximately 60° [B]
Inside [C]
•
Tighten:
Torque - Air Cleaner Housing Mounting Bolts: 20 N·m (2.0
kgf·m, 15 ft·lb)
Air Cleaner Housing Dust and/or Water Inspection
•
Push open the drain tube [A] on the bottom of the air cleaner housing.
Fuel Filter
•
Fuel Filter Removal
Tilt up the cargo bed.
•
Remove:
Clamp [A]
Fuel Hose [B]
Fuel Filter Mounting Bolts [C]
•
Remove:
Clamp [A]
Fuel Hose [B]
Fuel Filter [C]
Fuel Filter Installation
•
Install:
Fuel Filter
Fuel Hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter)
•
Tighten:
Torque - Fuel Filter Mounting Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
•
Bleed the air from the fuel filter.
○
Loosen the air vent plug [A].
○
Pump the priming button [B] until the fuel comes out of the air vent.
○
Tighten the air vent plug securely.
Torque - Air Vent Plug: 5.0 N·m (0.51 kgf·m, 44 in·lb)
○
Wipe up any spilled fuel.
•
Start the engine, and check for fuel leakage.
Fuel Filter Cartridge Replacement
•
Refer to the Fuel Filter Element Replacement in the Periodic Maintenance chapter.
Water Draining
•
Refer to the Fuel Filter Water Draining in the Periodic
Maintenance chapter.
FUEL SYSTEM 3-31
3-32 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.
•
Remove:
Front Seat Lower Cover Front and Rear (see Floor Center Panel Removal in the Frame chapter)
Fuel Tank Cap [A]
Screws [B]
Front Seat Lower Cover Right [C]
For KAF950G9
∼ GC/HA
•
Remove:
Clamps and Fuel Hoses [A]
Clamp and Air Vent Hose [B]
Bolt [C] and Washer
•
Remove:
Bolt [A], Washer and Nut
Bolt [B] and Washer
Fuel Tank [C]
•
For KAF950GD
•
Disconnect the fuel level gauge lead connector.
Remove the clamps and fuel hoses [A].
Fuel Tank
•
Remove the clamp [A] and air vent hose [B].
•
Remove the bolt [A] and washer.
•
Remove:
Bolt [A], Washer and Nut
Bolt [B] and Washer
Fuel Tank [C]
Fuel Tank Installation
•
Check that the dampers [A] are in place on the fuel tank.
[B] KAF950G9, GA/HA
[C] KAF950GB
∼
FUEL SYSTEM 3-33
3-34 FUEL SYSTEM
Fuel Tank
•
Replace the nut [G] with a new one.
•
Install the dampers [A] in the fuel tank as shown in the figure.
Thicker Side [B]
Front Side [C]
Collars [D]
Washers [E]
Bolts [F]
Nut
[I] KAF950G9
∼ GC/HA
[J] KAF950GD
Fuel Tank
•
Install the check valve [A] so that the arrow [B] faces fuel tank.
Black Color [C]
Blue Color [D]
•
Install the clamps [E].
[F] KAF950G9
∼ GC/HA
[G] KAF950GD
FUEL SYSTEM 3-35
•
Install:
Fuel Return Hose [A] and Clamp
Fuel Output Hose [B] and Clamp
•
Run the fuel hoses and air vent hose correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
•
Install the removed parts (see appropriate chapters).
Fuel Tank Cleaning/Inspection
WARNING
Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low flash-point solvents to clean the tank.
3-36 FUEL SYSTEM
Fuel Tank
•
Remove the fuel tank and drain it.
•
Remove:
Fuel Level Gauge (KAF950G9
∼ GC/HA, see Fuel Level
Gauge Removal)
Fittings [A], Seals [B] and Fuel Hoses [C]
•
Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.
•
Pour the solvent out of the tank.
•
Dry the tank with compressed air.
•
Visually inspect the following items for any damage.
Fuel Tank Cap Gasket
Fuel Level Gauge Gasket (KAF950G9
∼ GC/HA)
Seals
Replace the gaskets if they are damaged.
○
Push down the gasket [A] into the bottom of the fuel tank cap [B], and insert the flange portions [C] of the gasket to the cap threads.
Fuel Level Gauge Removal (KAF950G9
∼
GC/HA)
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.
•
•
Tilt up the seat.
Pry off the gauge cap [A] and discard the cap.
•
Check the grooves [B] in the fuel tank boss.
If the grooves are damaged by removing the cap or can not hold the cap nails, the fuel tank must be replaced.
•
Pull out the fuel level gauge [C].
Fuel Tank
Fuel Level Gauge Installation (KAF950G9
GC/HA)
∼
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.
•
Install the fuel level gauge so that the 1/2 scale [A] faces the left [B] of the vehicle.
•
Push the new gauge cap over the gauge so that the notch
[C] aligns with the 1/2 scale.
•
Check that the gauge cap nails fit securely in the grooves in the fuel tank boss.
Fuel Level Gauge Check (KAF950G9
∼
GC/HA)
•
Remove the fuel level gauge from the fuel tank (see Fuel
Level Gauge Removal).
•
Check that the float [A] moves up and down [B] smoothly without binding. It should go down under its own weight.
If the float does not move smoothly or has visual damage, replace the gauge.
Fuel Level Gauge Removal (KAF950GD)
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the main switch off. Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
NOTICE
Never drop the fuel level gauge, especially on a hard surface. Such a shock to the fuel level gauge can damage it.
•
Tilt up the seat.
•
Draw the fuel out from the fuel tank with a commercially available electric pump.
FUEL SYSTEM 3-37
3-38 FUEL SYSTEM
Fuel Tank
•
Remove:
Fuel Level Gauge Lead Connector [A]
Fuel Level Gauge Mounting Bolts [B]
Plate [C]
Fuel Level Gauge [D]
•
Discard the O-ring [A].
Fuel Level Gauge Installation (KAF950GD)
•
Remove dirt or dust from the fuel level gauge [A] by lightly applying compressed air.
•
Replace the O-ring with a new one and install it in the groove on the fuel tank.
•
Install the fuel level gauge [A] and plate [B], so that the projections [C] fit into the recesses.
•
Tighten:
Torque - Fuel Level Gauge Mounting Bolts: 4.0 N·m (0.41
kgf·m, 35 in·lb)
COOLING SYSTEM 4-1
Cooling System
Table of Contents
4
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
No.
Fastener
1 Coolant Drain Plug
2 Coolant Inlet Bolts
3 Coolant Reserve Tank Bolt
4 Coolant Temperature Switch
5 Fan Mounting Bolts
6 Radiator Fan Mounting Bolts
7 Radiator Fan Switch
8 Radiator Fan Switch
9 Radiator Mounting Bolts
10 Radiator Screen Mounting Bolts
11 Shroud Mounting Bolts
12 Thermostat Housing Cap Bolts
13 Water Pipe Mounting Bolts
14 Water Pump Mounting Bolts and Nuts
N·m
25
7.8
4.4
27
8.8
6.0
23
25
8.8
8.8
6.0
7.8
8.8
20
15. Blue Marks: Install the hoses so that their marks face upwards.
16. KAF950G9, GA/HA
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
0.61
2.3
2.5
0.90
0.90
0.61
0.80
0.90
2.0
Torque kgf·m
2.5
0.80
0.45
2.8
0.90
ft·lb
18
69 in·lb
39 in·lb
20
78 in·lb
53 in·lb
17
18
78 in·lb
78 in·lb
53 in·lb
69 in·lb
78 in·lb
15
Remarks
L
L
4-4 COOLING SYSTEM
Specifications
Item
Coolant
Type (Recommended)
Standard
Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)
Color
Mixed Ratio
Freezing Point
Green
Soft water 50%, coolant 50%
–35°C (–31°F)
Total Amount
Radiator Cap
4.4 L (4.7 US qt)
Relief Pressure
Thermostat
93
∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
Valve Opening Temperature 81
∼ 84°C (178 ∼ 183°F)
Valve Full Opening Temperature 95°C (203°F)
COOLING SYSTEM 4-5
Flow Chart
This engine has a pressurized, forced circulation cooling system.
The water pump circulates coolant through the cylinder block, cylinder head and radiator. The thermostat maintains optimum engine temperature.
The thermostat is equipped with a by-pass valve which permits coolant to re-circulate through the cylinder block and cylinder head.
As the engine warms, the by-pass valve closes as the thermostat opens, permitting complete circulation through the radiator.
Always maintain a 50% solution of phosphate free antifreeze at all times for adequate heat dissipation, lubrication and protection from freezing.
1. Water Pump
2. Thermostat
3. Air Bleed Bolt
4. Reserve Tank
5. Radiator
6. Radiator Cap
7. Drain Bolts
8. Front
4-6 COOLING SYSTEM
Coolant
Coolant Level Inspection
NOTE
○
Check the level when the engine is cold (room of ambient temperature).
NOTICE
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 reserve tank.
•
Tilt up the front cargo hood.
•
Check the coolant level in the reserve tank [A] with the vehicle parked on a level surface.
If the coolant level is lower than the L (Low) level line [C], remove the reserve tank cap [B], then add coolant to the
F (Full) level line [D].
NOTICE
For refilling, add the specified mixture of coolant and soft water.
Adding water alone dilutes the coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water can be added.
But the diluted coolant must be returned to the correct mixture ratio within a few days.
If coolant must be added often, or the reserve tank has run completely dry; there is probably leakage in the cooling system. Check the system for leaks.
Coolant Draining
•
Refer to the Coolant Change in the Periodic Maintenance chapter.
Coolant Filling
•
Refer to the Coolant Change in the Periodic Maintenance chapter.
•
Coolant Reserve Tank Removal
Tilt up the front cargo hood.
•
Remove:
Quick Rivets [A]
Tapping Screw [B] and Collar
Partition [C]
Coolant
•
•
Remove the coolant reserve tank mounting bolts [A].
Remove the cap and poor the coolant into a container.
•
Remove:
Reserve Tank Overflow Hose [B]
Radiator Overflow Hose [C]
Coolant Reserve Tank
Coolant Reserve Tank Installation
•
Installation is the reverse of removal, note the following.
○
Insert the projection [A] of the coolant reserve tank into the grommet [B] on the font cargo compartment.
○
Run the hoses according to the Cable, Wire, and Hose
Routing section in the Appendix chapter.
○
Fill the coolant reserve tank with coolant (see Coolant
Change in the Periodic Maintenance chapter).
COOLING SYSTEM 4-7
4-8 COOLING SYSTEM
Water Pump
Water Pump Removal
•
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
•
Remove the fan belt cover (see Cooling Fan Belt Inspection in the Periodic Maintenance chapter).
•
Loosen the cooling fan belt (see Cooling Fan Belt Inspection in the Periodic Maintenance chapter).
•
Remove:
Fan Mounting Bolts [A]
Spacer [B]
Water Pump Pulley [C]
Fan Belt [D]
•
Remove the bracket bolt [A], and move the fan belt adjusting bracket [B] forward.
•
Remove:
Water Pump Hose [A]
Coolant Temperature Switch Lead Connector [B]
Water Pump Mounting Nuts [C]
Water Pump Mounting Bolts [D]
Water Pump [E] and Bracket [F]
•
Water Pump Installation
Replace the water pump gasket with a new one.
•
Install the water pump.
Torque - Water Pump Mounting Bolts and Nuts: 20 N·m (2.0
kgf·m, 15 ft·lb)
•
Tighten:
Torque - Alternator Adjusting Bracket Bolts: 20 N·m (2.0
kgf·m, 15 ft·lb)
•
Adjust the fan belt deflection (see Cooling Fan Belt Inspection in the Periodic Maintenance chapter).
Water Pump
Water Pump Inspection
•
Check the drainage outlet passage at the top [A] and bottom [B] of the water pump body for coolant leakage.
If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passages. Replace the water pump unit.
COOLING SYSTEM 4-9
•
Remove the water pump pulley [A], and check it.
If the pulley is bent or damaged, replace the pulley.
•
Check the water pump bearings by rotating pulley flange
[A] by hand.
○
Make sure pulley rotates smoothly.
If the water pump shows evidence of the bearings are rough, replace the water pump unit.
4-10 COOLING SYSTEM
Radiator and Radiator Fan
Radiator Removal
WARNING
A spinning radiator fan can cause serious injury.
The radiator fan is connected directly to the battery and may start even if the main switch is off. Do not touch the radiator fan until it has been disconnected from the battery.
•
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
•
Remove:
Front Cover (see Front Cover Removal in the Frame chapter)
Radiator Fan Lead Connector [A]
•
Remove the water hoses [A].
•
Turn over the rubber cover [A].
•
Disconnect the radiator fan switch lead connectors [B].
•
Remove:
Radiator Mounting Bolts [A]
Radiator with Screen [B]
NOTICE
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Radiator and Radiator Fan
Radiator Installation
•
Install:
Dampers [A]
Washers [B]
Collars [C]
Washers [D]
○
Install the washers [D] so that the round side [E] faces to the collar [C].
•
Tighten:
Torque - Radiator Mounting Bolts [F]: 8.8 N·m (0.90 kgf·m,
78 in·lb)
•
Connect:
Radiator Fan Switch Lead Connectors
Radiator Fan Lead Connector
•
Install:
Radiator Hoses [G]
Reserve Tank Hose [H]
Clamps [I]
•
Run the hoses according to the Cable, Wire, and Hose
Routing section in the Appendix chapter.
Radiator Fan Removal
•
Remove:
Radiator
Radiator Fan Mounting Bolts [A]
Radiator Fan Assembly [B]
COOLING SYSTEM 4-11
•
Remove:
Shroud Mounting Bolts [A]
Shroud [B]
Radiator Fan Installation
•
Install the shroud [A] so that the recess [B] of the shroud fit on the stopper [C] of the radiator.
•
Tighten:
Torque - Shroud Mounting Bolts: 6.0 N·m (0.61 kgf·m, 53 in·lb)
•
Install:
Radiator Fan Assembly
Radiator Fan Mounting Bolts
•
Tighten:
Torque - Radiator Fan Mounting Bolts: 6.0 N·m (0.61 kgf·m,
53 in·lb)
4-12 COOLING SYSTEM
Radiator and Radiator Fan
Radiator Inspection
•
Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully straighten them.
If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparable deformed fins, replace the radiator.
Radiator Cleaning
•
Refer to the Radiator Cleaning in the Periodic Maintenance chapter.
Radiator Cap Inspection
•
Check the condition of the radiator cap valve seals [A] and valve spring [B].
If any one of them shows visible damage, replace the cap with a new one.
•
Install the cap [A] on a cooling system pressure tester [B].
NOTE
○
Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
•
Watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The gauge pointer must remain within the relief pressure range in the table below at least 6 seconds. Continue to pump the tester until the relief valve opens, indicated by the gauge pointer flicking downward. The relief valve must open within the specified range.
Radiator Cap Relief Pressure
Standard: 93
∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13
∼ 18 psi)
If the cap cannot hold the specified pressure, or if it holds too much pressure, replace the cap.
Thermostat
•
Thermostat Removal
Tilt up the cargo bed.
•
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
•
Remove:
Coolant Temperature Switch Lead Connector [A]
Thermostat Housing Cap Bolts [B]
Thermostat Housing Cap [C]
•
Remove:
Locating Screw [A]
Thermostat [B]
COOLING SYSTEM 4-13
•
Thermostat Installation
Replace the thermostat housing gasket with a new one.
•
Install the locating screw.
•
Tighten:
Torque - Thermostat Housing Cap Bolts: 7.8 N·m (0.80
kgf·m, 69 in·lb)
•
Adjust the coolant (see Coolant Change in the Periodic
Maintenance chapter).
Thermostat Inspection
•
Remove the thermostat, and inspect the thermostat valve
[A] at room temperature.
If the valve is open, replace the thermostat with a new one.
•
To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water.
○
The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water. It must not touch the container, either.
If the measurement is out of the specified range, replace the thermostat with a new one.
Thermostat Valve Opening Temperature
Standard: 81
∼ 84°C (178 ∼ 183°F)
Thermostat Valve Full Opening Temperature
Standard: 95°C (203°F)
4-14 COOLING SYSTEM
Hoses and Pipes
Hose and Pipe Installation
•
Install the hoses and pipes being careful to follow bending direction or diameter. Avoid sharp bending, kinking, flattening, or twisting.
•
Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting. This will prevent the hoses from working loose.
○
The clamp screws should be positioned correctly to prevent the clamps from contacting anything.
•
Install the water pipes [A].
•
Tighten:
Torque - Water Pipe Mounting Bolts [B]: 8.8 N·m (0.90
kgf·m, 78 in·lb)
Hose Inspection
•
Refer to the Radiator Hose and Connection Inspection in the Periodic Maintenance chapter.
Radiator Fan Switch, Coolant Temperature Switch
Radiator Fan Switch Removal
NOTICE
The fan switch or the coolant temperature switch should never be allowed to fall on a hard surface.
Such a shock to their parts can damage them.
•
Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
•
Remove the front cover (see Front Cover Removal in the
Frame chapter).
•
Turn over the rubber cover [A].
•
Remove:
Radiator Fan Switch Lead Connectors [B]
Radiator Fan Switch [C]
COOLING SYSTEM 4-15
•
Coolant Temperature Switch Removal
Tilt up the cargo bed.
•
Remove:
Coolant Temperature Switch Lead Connector [A]
Coolant Temperature Switch [B]
Radiator Fan Switch, Coolant Temperature Switch
Installation
•
Apply grease to the O-ring on the fan switch.
•
Apply a non-permanent locking agent to the threads of the coolant temperature switch.
•
Tighten the fan switch and coolant temperature switch.
Torque - Radiator Fan Switch: 25 N·m (2.5 kgf·m, 18 ft·lb)
Coolant Temperature Switch: 27 N·m (2.8 kgf·m,
20 ft·lb)
Radiator Fan Switch Inspection
•
Refer to the Radiator Fan Switch Inspection in the Electrical System chapter.
Coolant Temperature Switch Inspection
•
Refer to the Coolant Temperature Switch Inspection in the
Electrical System chapter.
ENGINE TOP END 5-1
Engine Top End
Table of Contents
5
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
No.
Fastener
1 Cylinder Head Bolts
2 Cylinder Head Cover Nuts
3 Exhaust Manifold Mounting Nuts
4 Inlet Manifold Mounting Bolts
5 Inlet Manifold Mounting Nuts
6 Rocker Arm Components Mounting Nuts
7 Valve Adjusting Screw Locknuts
8 Muffler Mounting Bolts
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
7.8
7.8
20
11
20
N·m
34
5.4
20
Torque kgf·m
3.5
0.55
2.0
0.80
0.80
2.0
1.1
2.0
ft·lb
25
48 in·lb
15
69 in·lb
69 in·lb
15
97 in·lb
15
Remarks
EO, S
L
5-4 ENGINE TOP END
Specifications
Item
Cylinder Head
Cylinder Compression
Cylinder Head Warp
Rocker Shaft and Rocker Arm
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Valve Lifters
Valve Lifter Outside Diameter
Valves
Valve Clearance
Valve Seating Surface:
Width:
Outside Diameter:
Inlet
Exhaust
Valve Seat Cutting Angle
Valve Spring Free Length
Valve Head Thickness
Valve Stem Diameter:
Inlet
Exhaust
Valve Guide Inside Diameter
Valve Guide Outside Diameter:
Standard Valve Guide
Replacement Valve Guide
Valve/Guide Clearance:
Inlet
Exhaust
Standard
3 330 kPa (34.0 kgf/cm²,
483 psi) at 300 r/min (rpm)
– – –
10.00
∼ 10.02 mm
(0.3937
∼ 0.3945 in.)
9.97
∼ 9.99 mm
(0.3925
∼ 0.3933 in.)
Service Limit
2 990 kPa (30.5 kgf/cm²,
434 psi) at 300 r/min
(rpm)
0.1 mm (0.004 in.)
10.03 mm (0.3949 in.)
9.957 mm (0.3920 in.)
17.98 mm (0.7079 in.)
0.20 mm (0.0079 in.)
0.8
∼ 1.2 mm (0.0315 ∼ 0.0472 in.)
17.91 mm (0.7051 in.)
– – –
– – –
28 mm (1.1024 in.)
24.5 mm (0.9646 in.)
32°, 45°, 60°
30.7 mm (1.2087 in.)
1.2 mm (0.0472 in.)
5.945
∼ 5.960 mm
(0.2341
∼ 0.2346 in.)
5.965
∼ 5.980 mm
(0.2348
∼ 0.2354 in.)
6.000
∼ 6.015 mm
(0.2362
∼ 0.2368 in.)
11.05 mm (0.4350 in.)
11.08 mm (0.4362 in.)
0.055
∼ 0.070 mm
(0.0022
∼ 0.0028 in.)
0.035
∼ 0.050 mm
(0.0014
∼ 0.0020 in.)
– – –
– – –
– – –
29.7 mm (1.1693 in.)
1.0 mm (0.0394 in.)
5.903 mm (0.2324 in.)
5.923 mm (0.2332 in.)
6.036 mm (0.2376 in.)
– – –
– – –
0.090 mm (0.0035 in.)
0.094 mm (0.0037 in.)
Special Tools
Outside Circlip Pliers:
57001-144
Valve Guide Arbor, 5.5:
57001-1021
Valve Seat Cutter, 45° - 27.5:
57001-1114
Valve Seat Cutter, 32° - 28:
57001-1119
Valve Seat Cutter, 30° - 30:
57001-1120
ENGINE TOP END 5-5
Valve Seat Cutter, 60° - 30:
57001-1123
Valve Seat Cutter Holder, 5.5:
57001-1125
Valve Seat Cutter Holder Bar:
57001-1128
Compression Gauge Adapter:
57001-1431
Valve Guide Driver:
57001-1432
5-6 ENGINE TOP END
Special Tools
Valve Spring Compressor:
57001-1433
ENGINE TOP END 5-7
Cylinder Head
•
Cylinder Compression Measurement
Tilt up the cargo bed.
•
Thoroughly warm up the engine so that the engine oil between the piston and the cylinder wall will help seal compression as it does during normal running.
•
Stop the engine, remove the glow plugs, and attach a compression gauge [A] firmly into the one glow plug hole.
Special Tool - Compression Gauge Adapter [B]: 57001
•
-1431
•
Wrap a tape around the glow plug lead (black/white) end to insulate.
•
Disconnect the fuel cut solenoid lead connector [C].
Using the starter motor, turn the engine over until the compression gauge stops rising; this is the highest compression reading obtainable.
Cylinder Compression
Standard: 3 330 kPa (34.0 kgf/cm², 483 psi) at 300 r/min (rpm)
Service Limit: 2 990 kPa (30.5 kgf/cm², 434 psi) at 300 r/min (rpm)
•
Repeat the measurement for the other cylinders.
○
The following table should be consulted if the obtainable compression reading is not within the specific range.
Problem
Cylinder compression is higher than standard.
Cylinder compression is lower than service limit.
Diagnosis
Carbon accumulation on piston and cylinder head, and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings.
Remedy (Action)
Remove the carbon deposits and replace damaged parts.
Incorrect cylinder head gasket thickness
Replace with a gasket of the proper thickness.
Gas leakage around cylinder head
Replace damaged gasket and check cylinder head warp.
Bad condition of valve seating Repair if possible.
Adjust Incorrect valve, piston/cylinder clearance
Piston seizure
Bad condition of piston ring and/or piston ring grooves.
Inspect the cylinder and liner and replace/repair as necessary.
Replace
Cylinder Head Removal
•
Remove:
Water Pump (see Water Pump Removal)
Fuel Injection Pipes (see Fuel Injection Pipe Removal in the Fuel System chapter)
Exhaust Pipe (see Exhaust Pipe Removal)
Rocker Arm Components (see Rocker Arm Components
Removal)
5-8 ENGINE TOP END
Cylinder Head
•
Remove:
Bolts [A] and Nuts
Engine Mount Stay [B]
Bolts [C]
Oil Level Gauge Pipe [D]
Bolts [E]
Plate [F]
•
Remove:
Glow Plug Caps [A]
Glow Plug Lead [B]
Glow Plug Connecting Plate [C]
Rocker Arm Push Rods [D]
Valve Stem Caps [E]
○
Mark the push rods so that they may be installed in their original positions.
•
Remove the coolant from the cylinder head, using a syringe [A] or some other suitable device, through the coolant inlet opening [B].
○
Insert the gauge tube [C] 10
∼ 11 cm (3.9 ∼ 4.3 in.) from the opening.
○
Pull the handle slowly to pump out the coolant until the coolant no longer comes out.
•
Remove the cylinder head bolts following loosening sequence [1
∼ 14].
•
Remove:
Cylinder Head
Cylinder Head Gasket
Cylinder Head Installation
•
Clean the mating surface of the cylinder head and the
• cylinder.
•
Replace the cylinder head gasket [A] with a new one.
Install the dowel pins [B].
Cylinder Head
•
Apply engine oil to the cylinder head bolts.
•
Tighten the cylinder head bolts in the order shown.
Torque - Cylinder Head Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
ENGINE TOP END 5-9
•
Apply engine oil and install the rocker arm push rods [A]
(in original locations if reused).
○
Face the recessed end [B] upward.
•
Install:
Valve Stem Caps
Rocker Arm Components (see Rocker Arm Components
Installation)
•
Inspect the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).
•
Install the removed parts (see appropriate chapters).
•
Cylinder Head Warp
Clean the cylinder head.
•
Lay a straightedge [A] across the lower surface, inlet and exhaust manifold mounting surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and the head.
If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.
Cylinder Head Warp
Service Limit: 0.1 mm (0.004 in.)
5-10 ENGINE TOP END
Rocker Shaft and Rocker Arm
Rocker Arm Components Removal
•
Remove:
Fan Belt Cover (see Cooling Fan Belt Inspection in the
Periodic Maintenance chapter)
Breather Hose [A]
Cylinder Head Cover Bolts [B] and Washers [C]
Cylinder Head Cover [D]
•
Turn the crankshaft pulley [A] clockwise so that the timing mark [B] on the pulley aligns with the reference point [C] on the timing cover.
○
Check that the rocker arms at #1 cylinder are free.
If not, turn the pulley one more turn to free the rocker arms.
•
Remove:
Rocker Arm Components Mounting Nuts [A] and Washers [B]
Rocker Arm Components [C]
Rocker Arm Components Installation
•
Install the rocker arm components.
Torque - Rocker Arm Components Mounting Nuts: 20 N·m
(2.0 kgf·m, 15 ft·lb)
•
Inspect the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).
•
Tighten:
Torque - Cylinder Head Cover Nuts: 5.4 N·m (0.55 kgf·m, 48 in·lb)
•
Install the breather hose [A].
○
Twist the breather hose so that the white marks [B] face upward and the center part is higher than both ends.
Rocker Shaft and Rocker Arm
Rocker Arm Components Disassembly
•
Remove:
Rocker Arm Components (see Rocker Arm Components
Removal)
Circlips [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
•
Remove:
Rocker Arms [A]
Rocker Arm Supports [B]
Washers [C]
Springs [D]
Set Bolt [E]
Rocker Shaft [F]
•
Rocker Arm Components Assembly
Apply engine oil to the all components.
•
Small grooves next to oil holes [A] in the rocker shaft [B] must face down.
•
Install the center rocker arm support [C] as shown in the figure, and tighten the set bolt.
Left Lower Oil Hole [D]
•
Install:
Rocker Arms [A]
Springs [B]
Rocker Arm Supports [C]
Washers [D]
New Circlips [E]
Special Tool - Outside Circlip Pliers: 57001-144
Rocker Arm/Shaft Wear
•
Measure the inside diameter [A] of the rocker arm.
If the bearing has worn past the service limit, replace the rocker arm.
Rocker Arm Inside Diameter
Standard: 10.00
∼ 10.02 mm (0.3937 ∼ 0.3945 in.)
Service Limit: 10.03 mm (0.3949 in.)
ENGINE TOP END 5-11
5-12 ENGINE TOP END
Rocker Shaft and Rocker Arm
•
Measure the diameter [A] of the rocker shaft.
If the shaft has worn past the service limit, replace the rocker shaft.
Rocker Shaft Diameter
Standard: 9.97
∼ 9.99 mm (0.3925 ∼ 0.3933 in.)
Service Limit: 9.957 mm (0.3920 in.)
Valve Lifters
Valve Lifter Removal
•
Remove:
Cylinder Head (see Cylinder Head Removal)
Valve Lifters [A]
○
Mark and record the valve lifter locations so that they can be installed in their original positions.
ENGINE TOP END 5-13
Valve Lifter Installation
•
Apply engine oil and install the valve lifters (original positions).
Valve Lifter Inspection
•
Measure the outside diameter of the valve lifters [A].
If the valve lifter has worn past the service limit, replace the lifter.
Valve Lifter Outside Diameter
Standard: 17.98 mm (0.7079 in.)
Service Limit: 17.91 mm (0.7051 in.)
5-14 ENGINE TOP END
Valves
Valve Clearance Inspection
•
Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Clearance Adjustment
•
Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter.
Valve Removal
•
Remove:
Cylinder Head (see Cylinder Head Removal)
Valve Stem Cap
○
Mark and record the valve stem cap locations so they can be installed in their original positions.
•
Using the valve spring compressor [A] remove the split keepers.
Special Tool - Valve Spring Compressor: 57001-1433
•
Remove:
Retainer [A]
Valve Spring [B]
•
Remove:
Valve [A]
Spring Seat [B]
Oil Seal [C]
•
Valve Installation
Replace the oil seal [A] with a new one.
•
Apply engine oil to the new oil seal.
•
Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation.
•
Install:
Oil Seal
Valve [B]
Spring Seat [C]
Valve Spring [D]
Retainer [E]
Split Keepers [F]
Valves
Valve Guide Removal
•
Remove:
Valve (see Valve Removal)
Spring Seat
Oil Seal
•
Hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
Special Tool - Valve Guide Arbor, 5.5: 57001-1021
Valve Guide Installation
•
Apply engine oil to the valve guide outer surface before installation.
•
Press the valve guide [A] in from the top of the head using the valve guide driver [B] until the driver bottoms on cylinder head.
Special Tool - Valve Guide Driver: 57001-1432
•
Valve Seat Inspection
Remove the valve (see Valve Removal).
•
Coat the valve seat with machinist’s dye.
•
Push the valve into the guide.
•
Rotate the valve against the seat with a lapping tool.
•
Pull the valve out, and check the seating pattern on the valve head. It must be the correct width [A] and even all the way around.
NOTE
○
The valve stem and guide must be in good condition, or this check will not be valid.
If the valve seating pattern is not correct, repair the seat.
•
Measure the outside diameter [B] of the seating pattern on the valve seat.
If the outside diameter of the valve seating pattern is too large or too small, repair the seat.
Valve Seating Surface [C]
Valve [D]
Valve Seat [E]
Good [F]
Too Wide [G]
Too Narrow [H]
Uneven [I]
Valve Seating Surface Width
Standard: 0.8
∼ 1.2 mm (0.0315 ∼ 0.0472 in.)
Valve Seating Surface Outside Diameter
Inlet: 28 mm (1.1024 in.)
Exhaust: 24.5 mm (0.9646 in.)
ENGINE TOP END 5-15
5-16 ENGINE TOP END
Valves
Valve Seat Repair
•
Follow the manufacturer’s instructions for use of valve seat cutters.
Special Tools - Valve Seat Cutter Holder, 5.5: 57001-1125
Valve Seat Cutter Holder Bar: 57001-1128
[For Inlet Valve Seat]
Valve Seat Cutter, 45° - 27.5: 57001-1114
Valve Seat Cutter, 60° - 30: 57001-1123
[For Exhaust Valve Seat]
Valve Seat Cutter, 32° - 28: 57001-1119
Valve Seat Cutter, 30° - 30: 57001-1120
If the manufacturer’s instructions are not available, use the following procedure.
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
NOTE
○
Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.
NOTE
○
Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent the following.
60° ........................... Cutter angle [B]
37.5
....................... Outer diameter of cutter [C]
Valves
•
Operating Procedures
Clean the seat area carefully.
•
Coat the seat with machinist’s dye.
•
Fit a 45° cutter into 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.
NOTICE
Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.
•
Measure the outside diameter of the seating surface with a vernier caliper.
If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
•
Measure the outside diameter of the seating surface with a vernier caliper.
If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
Original Seating Surface [B]
NOTE
○
Remove all pittings of flaws from 45° ground surface.
○
After grinding with 45° cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface distinct and 32° and 60° grinding operation easier.
○
When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
ENGINE TOP END 5-17
5-18 ENGINE TOP END
Valves
If the outside diameter [A] of the seating surface is too large, make the 32° grind described below.
If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.
•
Grind the seat at a 32° angle [B] until the seat outside diameter is within the specified range.
○
To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide.
○
Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to prevent overgrinding.
○
After making the 32° grind, return to the seat outside diameter measurement step above.
•
To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above.
If the seat width is too wide, make the 60° [A] grind described below.
If the seat width is within the specified range, lap the valve to the seat as described below.
•
Grind the seat at a 60° angle until the seat width is within the specified range.
○
To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide.
○
Turn the holder, while pressing down lightly.
○
After making the 60° grind, return to the seat width measurement step above.
Correct Width [B]
Valves
•
Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above.
○
Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
○
Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve.
○
Repeat the process with a fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
•
The seating area should be marked about in the middle of the valve face.
If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it.
•
Be sure to remove all grinding compound before assembly.
•
When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).
ENGINE TOP END 5-19
5-20 ENGINE TOP END
Valves
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 [A] with a new one.
Valve Spring Free Length
Standard: 30.7 mm (1.2087 in.)
Service Limit: 29.7 mm (1.1693 in.)
Valve Head Thickness
•
Measure the thickness [A] of the valve head.
If the valve head thickness is less than the service limit, replace the valve with a new one.
Valve Head Thickness
Standard:
Service Limit:
1.2 mm (0.0472 in.)
1.0 mm (0.0394 in.)
Valve Stem Diameter
•
Measure the diameter of the valve stem at specified distance from end of the valve [A] as shown in the figure.
35 mm (1.38 in.) [B]
If any single measurement is less than the service limit, replace the valve with a new one.
Valve Stem Diameter
Standard:
Inlet
Exhaust
5.945
∼ 5.960 mm (0.2341 ∼ 0.2346 in.)
5.965
∼ 5.980 mm (0.2348 ∼ 0.2354 in.)
Service Limit:
Inlet 5.903 mm (0.2324 in.)
Exhaust 5.923 mm (0.2332 in.)
Valve Guide Inspection
•
Measure the inside diameter of the valve guide.
If the valve guide has worn past the service limit, replace the valve guide or cylinder head.
Valve Guide Inside Diameter
Standard: 6.000
∼ 6.015 mm (0.2362 ∼ 0.2368 in.)
Service Limit: 6.036 mm (0.2376 in.)
○
Measure the outside diameter of the valve guide removed.
If the diameter is 11.05 mm (0.4350 in.), replace it with a replacement valve guide.
If the diameter is 11.08 mm (0.4362 in.), it is a replacement valve guide. Replace the cylinder head.
Valve Guide Outside Diameter
Standard Valve Guide: 11.05 mm (0.4350 in.)
Replacement Valve Guide: 11.08 mm (0.4362 in.)
ENGINE TOP END 5-21
5-22 ENGINE TOP END
Valves
Measuring Valve/Guide Clearance
•
Subtract the valve stem diameter from the valve guide inside diameter to get the valve/valve guide clearance.
Valve/Guide Clearance
Standard:
Inlet
Exhaust
0.055
∼ 0.070 mm (0.0022 ∼ 0.0028 in.)
0.035
∼ 0.050 mm (0.0014 ∼ 0.0020 in.)
Service Limit:
Inlet
Exhaust
0.090 mm (0.0035 in.)
0.094 mm (0.0037 in.)
Valve Stem Cap Inspection
•
Visually inspect the valve stem cap [A] for wear.
If the cap is worn, replace it.
Exhaust Pipe and Muffler
•
Exhaust Pipe Removal
Tilt up the cargo bed.
•
Remove:
Bolts [A] and Washers
Exhaust Pipe Cover [B]
•
Remove the exhaust pipe holder nuts [A].
•
Remove:
Joint Bolts and Nuts [A]
Exhaust Pipe [B]
Muffler Removal
•
Remove the joint bolts and nuts [A].
•
Remove:
Muffler Mounting Bolts [A] and washers
Muffler [B]
ENGINE TOP END 5-23
5-24 ENGINE TOP END
Exhaust Pipe and Muffler
•
Exhaust Pipe and Muffler Installation
Installation is the reverse of removal, note the following.
•
Tighten:
Torque - Muffler Mounting Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
•
Apply a non-permanent locking agent to the threads of the muffler mounting bolts.
•
Replace the exhaust pipe gasket and muffler connecting gasket with new ones.
•
After installation, thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts.
Exhaust Pipe and Muffler Inspection
•
Before removing, check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler joint.
If there are signs of leakage around the exhaust pipe gasket, it should be replaced. If the muffler-to-exhaust pipe joint leaks, tighten the joint bolts.
•
Check the exhaust pipe and muffler for dents, cracks, rust and holes.
If the exhaust pipe or muffler is damaged, it should be replaced for best performance and least noise.
Spark Arrester Cleaning
•
Refer to the Spark Arrester Cleaning in the Periodic Maintenance chapter.
CONVERTER SYSTEM 6-1
Converter System
Table of Contents
6
6-2 CONVERTER SYSTEM
Exploded View
Exploded View
No.
Fastener
1 Air Cleaner Housing Mounting Bolts
2 Air Cleaner Housing Mounting Bolts
3 Converter Cover Bolts
4 Drive Pulley Bolt
5 Drive Pulley Cover Bolts
6 Fan Cover Bolts
7 Inner Cover Bolts
8 Ramp Weight Nuts
9 Spider
10. KAF950G9 and GA/HA Early Models
R: Replacement Parts
CONVERTER SYSTEM 6-3
93
13
8.8
4.4
N·m
16
20
4.4
6.9
275
Torque kgf·m
1.6
2.0
0.45
9.5
1.3
0.90
0.45
0.70
28.0
ft·lb
12
15
39 in·lb
69
115 in·lb
78 in·lb
39 in·lb
61 in·lb
203
Remarks
R
6-4 CONVERTER SYSTEM
Exploded View
Exploded View
No.
Fastener
1 Converter Case Bolts (L = 55 mm)
2 Converter Case Bolts (L = 28 mm)
3 Driven Pulley Bolt
4 Inner Cover Nut
5 Wear Shoe Mounting Screws
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
TO: Apply transmission oil.
CONVERTER SYSTEM 6-5
N·m
27
20
93
8.8
1.1
Torque kgf·m
2.8
2.0
9.5
0.90
0.11
ft·lb
20
15
69
78 in·lb
10 in·lb
Remarks
L
L
L
R
L
6-6 CONVERTER SYSTEM
Specifications
Item Standard Service Limit
Drive Belt
Belt Width
Belt Deflection
34.1 mm (1.34 in.)
28
∼ 36 mm (1.10 ∼ 1.42 in.)
32.6 mm (1.28 in.)
– – –
Drive Pulley
Cover Bushing Inside Diameter 27.655
∼ 27.955 mm (1.089 ∼ 1.101 in.) 27.99 mm (1.102 in.)
Sheave Bushing Inside Diameter 38.055
∼ 38.155 mm (1.498 ∼ 1.502 in.) 38.19 mm (1.504 in.)
Ramp Weight Bushing Inside
Diameter
Spring Free Length
Shoe Side Clearance
Driven Pulley
7.000
∼ 7.091 mm (0.276 ∼ 0.280 in.)
77 mm (3.03 in.)
0.05
∼ 0.20 mm (0.0020 ∼ 0.0079 in.)
7.23 mm (0.28 in.)
– – –
– – –
Movable Sheave Bushing Inside
Diameter
39.655
∼ 39.965 mm (1.561 ∼ 1.573 in.)
40 mm (1.57 in.)
Wear Shoe Width
Spring Free Length
– – –
137.5 mm (5.41 in.)
16.4 mm (0.65 in.)
– – –
Special Tools
Outside Circlip Pliers:
57001-144
Bearing Driver Set:
57001-1129
Drive & Driven Pulley Holder:
57001-1412
Drive Pulley Puller Bolt:
57001-1429
Driven Pulley Holder:
57001-1465
CONVERTER SYSTEM 6-7
Drive & Driven Pulley Holder:
57001-1473
Drive Pulley Holder:
57001-1548
Drive Pulley Wrench:
57001-1549
Flywheel & Pulley Holder:
57001-1605
6-8 CONVERTER SYSTEM
Air Cleaner
Air Cleaner Housing Removal
•
Loosen:
Clamps [A]
•
Remove:
Air Ducts [B]
[C] KAF950G9 and KAF950GA/HA early models
[D] KAF950GA/HA late models and KAF950GB
∼
NOTICE
If dirt gets into the torque converter, excessive wear and loss of driving power may result.
•
Remove:
Air Cleaner Housing Bolts [A], Washers and Nuts
Air Cleaner Housing [B]
[C] KAF950G9 and KAF950GA/HA early models
[D] KAF950GA/HA late models and KAF950GB
∼
•
After removing the housing, stuff pieces of lint-free, clean cloth into the torque converter cover duct to keep dirt out of the torque converter.
NOTICE
If dirt gets into the torque converter, excessive wear and loss of driving power may result.
Air Cleaner
Air Cleaner Housing Installation
•
Install:
Air Cleaner Housing [A]
Bracket Bolt [B]
Washer [C]
Damper [D] (The shorter side faces lower side.)
Collar [E]
Nut [F]
For KAF950G9 and KAF950GA/HA Early Models
•
Tighten:
Torque - Air Cleaner Housing Mounting Bolts: 20 N·m (2.0
kgf·m, 15 ft·lb)
For KAF950GA/HA Late Models and KAF950GB
∼
•
Tighten:
Torque - Air Cleaner Housing Mounting Bolts: 16 N·m (1.6
kgf·m, 12 ft·lb)
•
Install the clamps [A] at about 3mm (0.12 in.) [B] from the end of air ducts.
•
Install the clamp [C] into the bare position from the end of air duct.
CONVERTER SYSTEM 6-9
Air Cleaner Element Removal
•
Tilt up the cargo bed.
For KAF950G9 and KAF950GA/HA Early Models
•
Remove:
Wingbolts [A]
Cap [B]
6-10 CONVERTER SYSTEM
Air Cleaner
For KAF950GA/HA Late Models and KAF950GB
∼
•
Remove:
Clamps [A]
Cap [B]
•
Remove the air cleaner element [A].
•
After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner duct to keep dirt out of the torque converter.
NOTICE
If dirt gets into the torque converter, excessive wear and loss of driving power may result.
Air Cleaner Element Cleaning/Inspection
•
Refer to the Converter Air Cleaner Element Cleaning/Inspection in the Periodic Maintenance chapter.
Torque Converter
•
Torque Converter Outer Cover Removal
Lift up the cargo easy to work.
•
Remove:
Converter Air Cleaner Housing (see Air Cleaner Housing
Removal)
Left Rear Wheel (see Wheel Removal in the
Wheels/Tires chapter)
Flap Stay (see Flap and Flap Stay Removal in the Frame chapter)
Left Rear Shock Absorber (see Rear Shock Absorber
Removal in the Suspension chapter)
Screws [A]
Cover [B]
•
Remove:
Converter Cover Bolts [A] and Collars
Torque Converter Outer Cover [B]
CONVERTER SYSTEM 6-11
•
Torque Converter Outer Cover Installation
Install the outer cover [A] as shown in the figure.
○
First, insert the rear side [B] of the outer cover in the frame.
•
Install the collars and converter cover bolts.
•
Tighten:
Torque - Converter Cover Bolts: 4.4 N·m (0.45 kgf·m, 39 in·lb)
Torque Converter Inner Cover Removal
•
Remove:
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Torque Converter Outer Cover (see Torque Converter
Outer Cover Removal)
Drive Pulley (see Drive Pulley Removal)
•
Loosen the clamp [A] and separate the air duct [B] from the cover.
6-12 CONVERTER SYSTEM
Torque Converter
•
Remove:
Inner Cover Bolts [A] and Collars
Clamps [B]
Nut [C]
•
Avoid the bracket [A] and remove the inner cover [B] upward.
•
Torque Converter Inner Cover Installation
Replace the nut [E] with a new one.
•
Install:
Inner Cover [A]
Clamps [B]
Inner Cover Bolts (L = 30 mm (1.18 in.)) [C]
Inner Cover Bolt (L = 35 mm (1.38 in.)) [D]
Nut
Collars [F]
When installing the trim, add the glue to the place between bolt hole and bolt hole.
•
Tighten:
Torque - Inner Cover Bolts: 4.4 N·m (0.45 kgf·m, 39 in·lb)
•
Inner Cover Nut: 8.8 N·m (0.90 kgf·m, 78 in·lb)
•
Install the drive pulley (see Drive Pulley Installation).
Install the removed parts (see appropriate chapters).
Torque Converter Case Removal
•
Remove:
Drive Pulley (see Drive Pulley Removal)
Driven Pulley (see Driven Pulley Removal)
Damper Bracket Nuts [A] (Loosen)
Torque Converter
•
Hold the left part of the rear axle bracket with a jack [A].
•
Remove:
Leaf Spring Mounting Nuts [B]
Leaf Spring Rods [C]
CONVERTER SYSTEM 6-13
•
Loosen the clamp [A] and remove the air duct [B] from the torque converter case.
•
Remove:
Converter Case Bolts [A]
Converter Case Nut [B] and Washer
Torque Converter Case [C]
•
Place an oil pan beneath the drive shaft of the transmission case.
○
Avoid the brake hose bracket [A] and remove the torque converter case [B] while pushing down the leaf spring rear end.
Torque Converter Case Installation
•
Be sure to install the following on the drive shaft and transmission case.
Collar [A]
O-ring [B]
•
Confirm the engine and transmission case position (see
Engine Installation in the Engine Removal/Installation chapter).
6-14 CONVERTER SYSTEM
Torque Converter
•
Replace the nut [B] with a new one.
•
Install:
Torque Converter Case [A]
Nut and Washer [C]
•
Apply a non-permanent locking agent to the following bolts and install them.
Converter Case Bolts (L = 55 mm (2.17 in.)) [D]
Converter Case Bolts (L = 28 mm (1.10 in.)) [E]
•
Tighten:
Torque - Converter Case Bolts (L = 55 mm): 27 N·m (2.8
kgf·m, 20 ft·lb)
Converter Case Bolts (L = 28 mm): 20 N·m (2.0
kgf·m, 15 ft·lb)
•
Tighten the damper bracket nuts in the order as shown in the figure.
Front [A]
Outside [B]
Torque - Damper Bracket Nuts:
First: 20 N·m (2.0 kgf·m, 15 ft·lb)
Second: 44 N·m (4.5 kgf·m, 32 ft·lb)
Final: 59 N·m (6.0 kgf·m, 44 ft·lb)
•
Install the removed parts (see appropriate chapters).
Torque Converter Case Disassembly
•
Remove:
Torque Converter Case [A] (see Torque Converter Case
Removal)
Oil Seal [B]
Ball Bearing [C]
Trims [D] (if necessary)
•
Torque Converter Case Assembly
Apply transmission oil to the ball bearing.
•
Press the ball bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
•
Apply grease to the oil seal lip.
•
Press the oil seal [B] in the case so that the oil seal surface is flush [C] with the case end.
When installing the trim, add the glue to the place between bolt hole and bolt hole.
Drive Belt
Drive Belt Removal
•
Remove:
Drive Pulley (see Drive Pulley Removal)
Torque Converter Inner Cover (see Torque Converter Inner Cover Removal)
NOTE
○
Before removing the drive belt, observe the direction of the belt’s printed information [A] (such as manufacturer’s name and arrow marks) is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed.
•
Remove the drive belt [B].
Drive Belt Installation
NOTE
○
Be sure the printed information faces the same direction so the belt rotates in the same direction as originally installed. When installing a new belt, install it so the printed information [A] can be read from beside the vehicle.
•
•
Installation is basically the reverse of removal.
Loop the belt over the driven pulley.
•
Install:
Torque Converter Inner Cover (see Torque Converter Inner Cover Installation)
Drive Pulley (see Drive Pulley Installation)
•
Put the transmission in neutral, and rotate the driven pulley to allow the belt to return to the top [A] of the sheaves, before measuring belt deflection.
CONVERTER SYSTEM 6-15
Drive Belt Inspection
•
Refer to the Drive Belt Inspection in the Periodic Maintenance chapter.
Drive Belt Deflection Inspection
•
Refer to the Drive Belt Deflection Inspection in the Periodic Maintenance chapter.
Drive Belt Deflection Adjustment
•
Refer to the Drive Belt Deflection Adjustment in the Periodic Maintenance chapter.
6-16 CONVERTER SYSTEM
Drive Pulley
Drive Pulley Removal
•
Remove:
Torque Converter Outer Cover (see Torque Converter
Outer Cover Removal)
Fan Cover Bolts [A]
Fan Cover [B]
•
Install the drive pulley holder [A] and tighten it with the three Allen bolts [B] as shown in the figure.
Special Tool - Drive Pulley Holder: 57001-1548
•
Remove the drive pulley bolt [C] and washers.
•
Using the drive pulley holder [A] and drive pulley puller bolt [B], remove the drive pulley [C] from the crankshaft.
Special Tools - Drive Pulley Puller Bolt: 57001-1429
Drive Pulley Holder: 57001-1548
Drive Pulley Disassembly
•
Hold the drive pulley holder [A] and drive & driven pulley holder [B] in a vise.
Special Tools - Drive & Driven Pulley Holder: 57001-1412
Drive & Driven Pulley Holder: 57001-1473
•
Set the pulley onto the pulley holder.
•
Remove:
Drive Pulley Cover Bolts [A]
Drive Pulley Cover [B]
Drive Pulley
•
Remove the spring [A].
•
Put the drive pulley wrench [A] on the spider [B] and tighten the bolt [C].
Special Tool - Drive Pulley Wrench: 57001-1549
•
Remove the spider with the movable sheave.
•
Remove:
Spider [A]
Shoes [B]
Nuts [C]
Ramp Weight Pin [D]
Ramp Weight [E]
Movable Sheave [F]
Fixed Sheave [G]
CONVERTER SYSTEM 6-17
Drive Pulley Inspection
If the sheave surfaces [A] appear damaged, replace the sheaves.
6-18 CONVERTER SYSTEM
Drive Pulley
•
Replace any sheave which has uneven wear on the belt contacting surface.
Sheave Surfaces [A]
Straight Edge [B]
If the cover bushing is damaged or worn, replace the drive pulley cover.
Cover Bushing Inside Diameter [A]
Standard: 27.655
∼ 27.955 mm (1.089 ∼ 1.101 in.)
Service Limit: 27.99 mm (1.102 in.)
If the sheave bushing is damaged or worn, replace it.
Sheave Bushing Inside Diameter [A]
Standard: 38.055
∼ 38.155 mm (1.498 ∼ 1.502 in.)
Service Limit: 38.19 mm (1.504 in.)
If the spider shoes [A] are damaged, replace them.
•
Check the spider shoe side clearance (see Spider Shoe
Side Clearance Adjustment).
If the ramp weights [A] are damaged or worn, replace them.
If the pins [B] are damaged, replace them.
Drive Pulley
If the ramp weights are damaged or worn, replace them.
Rump Weight Bushing Inside Diameter [A]
Standard: 7.000
∼ 7.091 mm (0.276 ∼ 0.280 in.)
Service Limit: 7.23 mm (0.28 in.)
CONVERTER SYSTEM 6-19
If the rollers [A] are damaged or worn, replace the spider
[B].
If the washers [C] are damaged or worn, replace the spider.
If the spring is damaged, replace the spring.
Spring Free Length [A]
Standard: 77 mm (3.03 in.)
Spider Shoe Side Clearance Adjustment
•
Remove:
Drive Pulley (see Drive Pulley Removal)
Drive Pulley Cover and Spring (see Drive Pulley Disassembly)
•
Set the drive pulley [A] without the spring onto the pulley holders.
Special Tools - Drive & Driven Pulley Holder: 57001-1412
Drive & Driven Pulley Holder: 57001-1473
•
Install the following parts temporarily.
Dowel Pins
Drive Pulley Cover [B]
Two Bolts [C] (at Dowel Pins)
6-20 CONVERTER SYSTEM
Drive Pulley
•
Turn the spider counterclockwise.
•
Measure the resulting clearance [A] between the shoe [B] and the post [C] on the movable sheave at four posts, using a thickness gauge [D].
Shoe Side Clearance
Standard: 0.05
∼ 0.20 mm (0.0020 ∼ 0.0079 in.)
If the clearance is not within the specified range, adjust it according to following chart.
Clearance Measurement
up to 0.05 mm (0.0020 in.)
Present Shoes
Part Number Thickness
49048-1087
7.2 mm
(0.283 in.)
7.3 mm
49048-1088
49048-1089
(0.287 in.)
7.4 mm
(0.291 in.) over 0.05 to 0.20 mm no change
(over 0.0020 to 0.0079 in.) (49048-1090) (7.5 mm)
(standard clearance) (0.295 in.)
49048-1091
49048-1092
7.6 mm
(0.299 in.)
7.7 mm
(0.303 in.) over 0.20 mm (0.0079 in.)
49048-1093
49048-1094
49048-1095
7.8 mm
(0.307 in.)
7.9 mm
(0.311 in.)
8.0 mm
(0.315 in.)
•
Check that the movable sheave [A] moves smoothly, after the shoe side clearance adjustment.
○
The movable sheave must move freely towards the fixed sheave [B].
If the movable sheave does not move smoothly, readjust the shoe side clearance.
Drive Pulley
•
Drive Pulley Assembly
Replace the ramp weight nuts [B] with new ones.
•
Install the ramp weight [A] as shown in the figure.
•
Tighten:
Torque - Ramp Weight Nuts: 6.9 N·m (0.70 kgf·m, 61 in·lb)
•
Check that the ramp weights swing smoothly.
CONVERTER SYSTEM 6-21
•
Hold the fixed sheave [A] with the drive pulley holders [B] in a vise.
Special Tools - Drive & Driven Pulley Holder: 57001-1412
Drive & Driven Pulley Holder: 57001-1473
•
Clean the threads of the fixed sheave and spider.
•
Install:
Movable Sheave
Spider [A] and Shoes [B]
○
Align the arrow [C] on the spider with the arrow [D] on the movable sheave.
○
Insert the shoes so that the rubber side faces inward.
•
Put the drive pulley wrench [A] on the spider [B] and tighten the bolt [C].
Special Tool - Drive Pulley Wrench: 57001-1549
•
Turn the wrench for tightening.
Torque - Spider: 275 N·m (28.0 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.
•
Install:
Dowel Pins [C]
Drive Pulley Cover [D]
•
Tighten:
Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 115 in·lb)
•
Clean the surface of the sheaves with an oil-less cleaning fluid.
6-22 CONVERTER SYSTEM
Drive Pulley
Bushing Installation
•
Press the cover bushing [A] into the cover [B] using the special tool so that the end of bushing is flush with the shoulder [C] in the hole.
Special Tool - Bearing Driver Set: 57001-1129
•
Press the sheave bushing [A] into the movable sheave [B] using the special tool so that the end of bushing is flush with the shoulder [C] in the hole.
Special Tool - Bearing Driver Set: 57001-1129
Drive Pulley Installation
•
Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone, and wipe off any oil with a clean cloth from the tapers.
Fixed Sheave Tapered Portion [A]
Crankshaft Tapered Portion [B]
WARNING
These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.
•
Install the drive pulley, and screw in the drive pulley bolt with the stepped collar [A] and washers [B] as shown in the figure.
Bolt Head [C]
•
Hold the drive pulley with the drive pulley holder [A].
Special Tool - Drive Pulley Holder: 57001-1548
•
Tighten:
Torque - Drive Pulley Bolt [B]: 93 N·m (9.5 kgf·m, 69 ft·lb)
Drive Pulley
•
Press the ramp weight bushing [B] from the arrow side [A] into the ramp weight [C] using the special tool so that the end of bushing is flush with the shoulder [D] in the hole.
Special Tool - Bearing Driver Set: 57001-1129
CONVERTER SYSTEM 6-23
•
Install the fan cover.
Torque - Fan Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
•
Install the torque converter outer cover (see Torque Converter Outer Cover Installation).
6-24 CONVERTER SYSTEM
Driven Pulley
Driven Pulley Removal
•
Remove:
Drive Pulley (see Drive Pulley Removal)
Torque Converter Inner Cover (see Torque Converter Inner Cover Removal)
Drive Belt (see Drive Belt Removal)
•
Using a flywheel & pulley holder [A], remove the driven pulley bolt [B] and stepped collar.
Special Tool - Flywheel & Pulley Holder: 57001-1605
•
Remove the driven pulley.
Driven Pulley Disassembly
•
Hold the drive & driven pulley holder [A] in a vise.
Special Tool - Drive & Driven Pulley Holder: 57001-1412
•
Screw the guide bar [B] of the driven pulley holder into the holder.
•
Special Tool - Driven Pulley Holder: 57001-1465
Put the driven pulley [C] on the guide bar.
•
Tighten the nut [D], and compress the spring with the spring holder [E] of the driven pulley holder.
Special Tool - Driven Pulley Holder: 57001-1465
•
Remove the circlip [A] with circlip pliers [B].
Special Tool - Outside Circlip Pliers: 57001-144
•
Remove the nut and spring holder [C].
Driven Pulley
•
Remove:
Circlip [A]
Washer [B]
Ramp [C]
Spring [D]
Movable Sheave [E]
Spacer [F]
Fixed Sheave with Shaft [G]
CONVERTER SYSTEM 6-25
•
Remove:
Wear Shoe Mounting Screws [A]
Wear Shoes [B]
Driven Pulley Inspection
If the sheave surfaces [A] appear damaged, replace the sheaves.
•
Replace any sheave which has uneven wear on the belt contacting surface.
Straight Edge [B]
If the guide bushings [A] are damaged or worn, replace the movable sheave.
Sheave Bushing Inside Diameter
Standard: 39.655
∼ 39.965 mm (1.561 ∼ 1.573 in.)
Service Limit: 40 mm (1.57 in.)
6-26 CONVERTER SYSTEM
Driven Pulley
If the splines [A] of the fixed sheave and ramp are damaged or worn, replace them.
If the spring is damaged, replace the spring.
Spring Free Length [A]
Standard: 137.5 mm (5.41 in.)
If the tabs on the spring are misaligned or the spring coils are distorted, replace the spring.
○
One side end [B] of the spring must be maintained to ±10° from other side end.
Converter Driven Pulley Shoe Inspection
•
Refer to the Converter Driven Pulley Shoe Inspection in the Periodic Maintenance chapter.
Driven Pulley
Driven Pulley Assembly
•
Install the wear shoes [A] on the movable sheave [B] as shown in the figure.
○
The wear shoe shall be installed so that the mark [C] on the shoe faces outward.
•
Apply a non-permanent locking agent to the wear shoe mounting screws.
•
Tighten:
Torque - Wear Shoe Mounting Screws: 1.1 N·m (0.11 kgf·m,
10 in·lb)
•
Hold the fixed sheave 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 the spacer(s) [A] on the fixed sheave [B].
CONVERTER SYSTEM 6-27
•
Install:
Movable Sheave [A]
Spring [B]
○
Insert the spring end into the hole [C] on the movable sheave.
•
Install the ramp [A] on the fixed sheave shaft.
•
Insert the spring end [B] into the hole “1” on the ramp.
•
Put the washer [C] and circlip [D] on the ramp.
○
The washer shall be installed so that the recess of it faces outward.
•
Install the spring holder [A].
•
Align the flat portions [B] of spline of the fixed sheave and ramp, and push down the ramp halfway by tightening the flange nut [C].
•
Hold the movable sheave [D] by turning it counterclockwise 120º and tighten the flange nut until the bottom of ramp hits the movable sheave.
•
Install the washer and new circlip.
Special Tool - Outside Circlip Pliers: 57001-144
•
Release the movable sheave slowly until it stops naturally.
6-28 CONVERTER SYSTEM
Driven Pulley
Driven Pulley Installation
•
Clean the transmission driven shaft [A], and apply molybdenum disulfide grease width the specified range on it.
20
∼ 25 mm (0.79 ∼ 0.98 in.) [B]
5
∼ 10 mm (0.20 ∼ 0.39 in.) [C]
○
Apply molybdenum disulfide grease thinly in the area [C].
•
Install the driven pulley [D].
•
Install the stepped collar [A] on the pulley as shown in the figure.
Bolt Head [B]
•
Apply a non-permanent locking agent to the threads of the driven pulley bolt.
•
Using a flywheel & pulley holder [A], tighten the driven pulley bolt [B].
Special Tool - Flywheel & Pulley Holder: 57001-1605
Torque - Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
•
Install the removed parts (see appropriate chapters).
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System
Table of Contents
7
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
Exploded View
No.
Fastener
1 Engine Oil Drain Plugs
2 Oil Filter Stud Bolt
3 Oil Nozzle
4 Oil Pan Bolts and Nuts
5 Oil Pressure Switch
6 Oil Pump Drive Gear Bolt
7 Oil Strainer Mounting Bolt and Nuts
8 Relief Valve Bolt
EO: Apply engine oil.
G: Apply grease.
LG: Apply liquid gasket.
R: Replacement Parts
SS: Apply silicone sealant.
ENGINE LUBRICATION SYSTEM 7-3
7.8
14
20
7.8
39
N·m
34
44
14
Torque kgf·m
3.5
4.5
1.4
0.80
1.4
2.0
0.80
4.0
ft·lb
25
32
10
69 in·lb
10
15
69 in·lb
29
Remarks
SS
7-4 ENGINE LUBRICATION SYSTEM
Specifications
Item
Engine Oil and Oil Filter
Engine Oil:
Grade
Viscosity
Capacity
Standard
API CF or CF-4
SAE 10W-40
3.0 L (3.2 US qt)
(When filter is not removed)
3.3 L (3.5 US qt)
(When filter is removed)
Between F and L marks on dipstick Level
Oil Pump
Oil Pump Side Clearance
Oil Pump Housing Depth
Service Limit
– – –
– – –
– – –
– – –
– – –
0.030
∼ 0.096 mm (0.0012 ∼ 0.0038 in.)
0.15 mm
(0.0059 in.)
12.63
∼ 12.67 mm (0.4972 ∼ 0.4988 in.)
12.72 mm
(0.5008 in.)
Relief Valve
Relief Valve Spring Free Length
Oil Pressure Measurement
Oil Pressure
34.5
∼ 36.5 mm (1.358 ∼ 1.437 in.)
196
∼ 490 kPa (2.0 ∼ 5.0 kgf/cm²,
28
∼ 71 psi) at 3 000 r/min (rpm), Oil temperature 55
∼ 65°C (131 ∼ 149°F)
– – –
– – –
Special Tools and Sealant
Oil Pressure Gauge, 10 kgf/cm²:
57001-164
ENGINE LUBRICATION SYSTEM 7-5
Liquid Gasket, TB1211:
56019-120
Oil Pressure Gauge Adapter, PT 1/8:
57001-1033
7-6 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
This engine has a full pressure lubrication system with an oil filter. The gear driven oil pump draws oil from a screened oil pickup in the oil pan and pumps the oil through the oil filter.
The filtered oil flows through oil galleries in the crankcase and is distributed to the main bearings, connecting rod bearings, camshaft bearings and rocker arm shaft.
A pressure relief valve limits the maximum oil pressure in the system.
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. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
Oil Level Inspection
NOTE
○
If the vehicle has just been used, wait several minutes for all the oil to drain down.
○
If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles.
NOTICE
Racing the engine before the oil reaches every part can cause engine seizure.
•
Park the vehicle on level ground, and tilt up the seat.
•
Pull out the dipstick [A] out of the dipstick tube, wipe it dry, and insert it into the tube securely.
•
Pull out the dipstick and check the oil level. The oil level should be between the upper (F) and lower (L) level marks
[A].
If the oil level is too high, remove the excess oil. Remove the dipstick pipe, and using a syringe or some other suitable device through the opening, or removing the engine oil drain plug, drain the excess oil.
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine.
Oil Filler Cap [A]
NOTE
○
If the engine oil type and make are unknown, use any brand of the specified oil to top up the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely.
NOTICE
To avoid the engine damage, do not fill the engine oil above the full level.
Engine Oil and/or Oil Filter Change
•
Refer to the Engine Oil and/or Oil Filter Change in the
Periodic Maintenance chapter.
Oil Filter Removal
•
Refer to the Oil Filter Removal in the Periodic Maintenance chapter.
Oil Filter Installation
•
Refer to the Oil Filter Installation in the Periodic Maintenance chapter.
ENGINE LUBRICATION SYSTEM 7-9
Oil Pan and Oil Strainer
Oil Pan and Oil Strainer Removal
•
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Flywheel and End Plate (see End Plate Removal in the
Crankshaft/Crankcase chapter)
Oil Pan Bolts [A] and Nuts [B]
•
Remove the oil pan [C] straight so that the baffle plate in the oil pan does not to hitch the oil strainer.
•
Remove:
Oil Strainer Mounting Bolt [A] and Nuts [B]
Oil Strainer [C]
•
Oil Pan and Oil Strainer Installation
•
Clean the oil pan and oil strainer thoroughly whenever they are removed.
•
Replace the oil strainer gasket [A] with a new one.
Tighten:
Torque - Oil Strainer Mounting Bolt and Nuts: 7.8 N·m (0.80
kgf·m, 69 in·lb)
•
Apply liquid gasket [A] to the mating surface as shown in the figure.
Sealant - Three Bond: 1207F
•
Install the oil pan [B] so that the baffle plate [C] does not hitch the oil strainer.
•
Tighten:
Torque - Oil Pan Bolts and Nuts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Oil Strainer Cleaning/Inspection
•
Clean the oil strainer, and remove any particles stuck to it.
NOTE
○
While cleaning the strainer, check for any metal particles that might indicate internal engine damage.
•
Check the screen [A] carefully for any damage: holes and broken wire.
If the screen is damaged, replace the oil strainer.
7-10 ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
•
Remove:
Timing Gear Case (see Timing Gear Case Removal in the Crankshaft/Crankcase chapter)
Oil Pump Outer Rotor [A]
Oil Pump Installation
•
Clean and lubricate the oil pump outer rotor [A] with engine oil.
•
Apply engine oil to the oil pump outer rotor.
•
Install the oil pump outer rotor with the punch mark [B] facing inside.
•
Install the timing gear case (see Timing Gear Case Installation in the Crankshaft/Crankcase chapter).
Oil Pump Inspection
•
Remove the timing gear case cover (see Timing Gear
Case Removal in the Crankshaft/Crankcase chapter).
•
Set up a dial gauge [A] against the oil pump gear [B] as shown in the figure and measure the oil pump side clearance.
Oil Pump Side Clearance
Standard: 0.030
∼ 0.096 mm (0.0012 ∼ 0.0038 in.)
Service Limit: 0.15 mm (0.0059 in.)
If the clearance exceeds the service limit, go to next procedure.
•
Remove the oil pump outer rotor (see Oil Pump Removal).
•
Measure the depth of the pump housing in the crankcase
[A] with a depth micrometer [B] at several points.
Oil Pump Housing Depth
Standard: 12.63
∼ 12.67 mm (0.4972 ∼ 0.4988 in.)
Service Limit: 12.72 mm (0.5008 in.)
If the depth exceeds the service limit, replace the crankcase.
If the depth within the service limit, replace the timing gear case.
•
Visually inspect the oil pump inner rotor [A] and outer rotor
[B].
If there is any damage or uneven wear, replace the timing gear case [C].
ENGINE LUBRICATION SYSTEM 7-11
Relief Valve
Relief Valve Removal
•
Drain the engine oil (see Engine Oil and/or Oil Filter
Change in the Periodic Maintenance chapter).
•
Remove:
Relief Valve Bolt [A] and Washer
Relief Valve Spring
Relief Valve Plunger
Relief Valve Installation
•
Install:
Relief Valve Plunger [A]
Relief Valve Spring [B]
Washer [C] and Relief Valve Bolt [D]
•
Tighten:
Torque - Relief Valve Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Relief Valve Inspection
•
Visually inspect the relief valve spring [A] and plunger [B].
If any nicks or burrs are found during the above inspection, replace the parts.
•
Measure the relief valve spring free length.
If the spring is shorter than the standard, replace the spring.
Relief Valve Spring Free Length
Standard: 34.5
∼ 36.5 mm (1.358 ∼ 1.437 in.)
7-12 ENGINE LUBRICATION SYSTEM
Oil Pressure Measurement
Oil Pressure Measurement
•
Remove the oil pressure switch (see Oil Pressure Switch
Removal).
•
Attach the adapter [A] and gauge [B] to the hole.
Special Tools - Oil Pressure Gauge,10kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, PT 1/8: 57001
-1033
•
Install the removed parts (see appropriate chapters).
•
Start the engine and warm up the engine.
•
Run the engine at the specified speed, and read the oil pressure gauge.
Oil Pressure
Standard: 196
∼ 490 kPa (2.0 ∼ 5.0 kgf/cm², 28
∼ 71 psi) at 3 000 r/min (rpm), oil
temperature 55
∼ 65°C (131 ∼ 149°F)
•
Stop the engine.
•
Remove the oil pressure gauge and adapter.
WARNING
Hot oil can cause severe burns. Beware of hot engine oil that will drain through the oil passage when the gauge adapter is removed.
•
Install the oil pressure switch (see Oil Pressure Switch
Installation).
Troubleshooting Guide
Low Oil Pressure
Engine RPM too low
Wrong viscosity or diluted oil
Low oil level
Broken relief valve spring
Missing relief valve plunger
Worn bearings
Damaged or defective oil pump
High Oil Pressure
Wrong viscosity oil
Plugged oil galleries
ENGINE LUBRICATION SYSTEM 7-13
Oil Pressure Switch
Oil Pressure Switch Removal
•
Drain the engine oil (see Engine Oil and/or Oil Filter
Change in the Periodic Maintenance chapter).
•
Remove:
Fuel Injection Pipes (see Fuel Injection Pipe Removal in the Fuel System chapter)
Oil Level Gauge Pipe [A] (see End Plate Removal in the
Crankshaft/Crankcase chapter)
Bolt [B]
Plate [C]
Switch Connector [D]
Oil Pressure Switch [E]
Oil Pressure Switch Installation
•
Apply silicone sealant to the threads of the oil pressure switch and tighten it.
Sealant - Liquid Gasket, TB1211: 56019-120
Torque - Oil Pressure Switch: 14 N·m (1.4 kgf·m, 10 ft·lb)
•
Install the removed parts (see appropriate chapters).
7-14 ENGINE LUBRICATION SYSTEM
Oil Nozzle
Oil Nozzle Installation
•
Refer to the Timing Gear Case Installation in the Crankshaft/Crankcase chapter.
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
Exploded View
No.
Fastener
1 Engine Mounting Bolts
2 Stay Rod Rear Nut
L: Apply a non-permanent locking agent.
ENGINE REMOVAL/INSTALLATION 8-3
N·m
44
88
Torque kgf·m
4.5
9.0
ft·lb
32
65
Remarks
8-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Assembly Jig:
57001-1566
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine Removal
•
Disconnect the battery cables (see Battery Removal in the
Electrical System chapter).
•
Drain:
Engine Oil (see Engine Oil and/or Oil Filter Change in the Periodic Maintenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
○
Drain the coolant from the cylinder head if necessary (see
Cylinder Head Removal in the Engine Top End chapter).
•
Remove:
Cargo Bed (see Cargo Bed Removal in the Frame chapter)
Torque Converter Case (see Torque Converter Case Removal in the Converter System chapter)
•
Disconnect:
Oil Pressure Switch Lead Connector [A]
Glow Plug Lead [B]
Coolant Temperature Switch Lead Connector [C]
•
Remove:
Water Hose [D]
Fuel Hoses [E]
Air Duct [F] (see Fuel Pipe Removal in the Fuel System chapter)
•
Remove:
Bracket Bolts [A]
Engine Mount Stay [B]
Throttle Cable End Rod [C]
Fuel Cut Solenoid Lead Connector [D]
•
Remove:
Water Hose [A]
Alternator Lead Connector [B]
Alternator Cable [C]
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
•
Remove:
Starter Motor Lead Connector [A]
Starter Motor Cable [B]
Engine Ground Cable [C]
•
Remove the engine mounting bolts [A] and washers.
•
Remove the engine [A].
•
Remove:
Engine Bracket Bolts [A] (Both Sides)
Engine Bracket [B]
ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
•
Engine Installation
Install the engine on the bracket.
•
Apply a non-permanent locking agent to the threads of the engine bracket bolts and tighten them.
•
Adjust the engine mounting position for alignment of the torque converter.
○
Mount the engine and install the engine mounting bolts loosely.
○
Install the assembly jig [A] onto the transmission driven shaft and crankshaft as shown in the figure.
Special Tool - Assembly Jig: 57001-1566
○
Screw in the bolt [B] until the assembly jig is fitted to the transmission driven shaft. The length [C] between the jig and the end of coupling is 5 mm (0.20 in.).
○
Tighten:
Torque - Engine Mounting Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)
○
Remove the assembly jig.
•
Install the removed parts (see appropriate chapters).
•
Tighten:
Torque - Stay Rod Rear Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)
•
Adjust:
Engine Oil (see Engine Oil and/or Oil Filter Change in the Periodic Maintenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
CRANKSHAFT/CRANKCASE 9-1
Crankshaft/Crankcase
Table of Contents
9
9-2 CRANKSHAFT/CRANKCASE
Exploded View
Exploded View
No.
Fastener
1 Camshaft Drive Gear Bolt
2 Camshaft Retainer Bolts
3 Connecting Rod Cap Nuts
4 Coolant Drain Plug
5 Crankshaft Main Bearing Cap Bolts
6 Crankshaft Pulley Bolt
7 End Plate Bolts
8 Flywheel Mounting Bolts
9 Fuel Injection Pump Drive Gear Nut
10 Idle Gear Bolts
11 Oil Nozzle
12 Oil Pump Drive Gear Bolt
13 Oil Seal Retainer Bolts
14 Timing Gear Case Bolts
15 Timing Gear Case Cover Bolts
EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
R: Replacement Parts
S: Follow the specified tightening sequence.
CRANKSHAFT/CRANKCASE 9-3
20
5.4
7.8
7.8
44
64
25
14
25
59
98
39
N·m
43
7.8
36
10.0
4.0
4.5
6.5
2.5
1.4
2.0
0.55
0.80
0.80
Torque kgf·m
4.4
0.80
3.7
2.5
6.0
32
47
18
10
15
48 in·lb
69 in·lb
69 in·lb
ft·lb
32
69 in·lb
27
18
44
72.3
29
Remarks
L
EO
L, S
9-4 CRANKSHAFT/CRANKCASE
Specifications
Item
Timing Gear Case
Timing Gear Backlash
Standard
Idle Gear Inside Diameter
Idle Gear Shaft Outside Diameter
– – –
– – –
– – –
Camshaft
Cam Height:
Inlet
Exhaust
Camshaft Journal Diameter:
Right Side
30.065
∼ 30.135 mm
(1.1837
∼ 1.1864 in.)
30.065
(1.1837
∼ 30.135 mm
∼ 1.1864 in.)
Center
Left Side
Camshaft Runout
35.959
∼ 35.975 mm
(1.4157
∼ 1.4163 in.)
35.910
∼ 35.955 mm
(1.4138
∼ 1.4155 in.)
35.910
∼ 35.955 mm
(1.4138
∼ 1.4155 in.)
– – –
Crankshaft and Connecting Rods
Connecting Rod Big End Side
Clearance
Connecting Rod Small End:
Inside Diameter
Connecting Rod Big End:
Out of Round
0.15
∼ 0.28 mm
(0.0059
∼ 0.0110 in.)
– – –
– – –
Connecting Rod Thrust Faces:
Distortion – – –
Crankshaft Main Journal Diameter 41.976
∼ 42.000 mm
(1.6526
∼ 1.6535 in.)
Crankshaft Crankpin Diameter 36.976
∼ 37.000 mm
(1.4557
∼ 1.4567 in.)
Crankshaft Out of Round and Taper – – –
Undersize Crankshaft Main
Bearing Inserts
Crankshaft #3 Main Journal Runout
0.25 mm (0.0098 in.) Undersize
– – –
Crankshaft Side Clearance
Oversize Thrust Washers
0.02
∼ 0.24 mm
(0.0008
∼ 0.0094 in.)
0.12 mm (0.0047 in.)
Oversize
Service Limit
0.2 mm
(0.008 in.)
34.17 mm
(1.3453 in.)
33.91 mm
(1.3350 in.)
29.965 mm
(1.1797 in.)
29.965 mm
(1.1797 in.)
35.89 mm
(1.413 in.)
35.84 mm
(1.411 in.)
35.84 mm
(1.411 in.)
0.03 mm
(0.0012 in.)
0.3 mm
(0.0118 in.)
18.03 mm (0.7098 in.)
0.02 mm
(0.0008 in.)
0.05 mm
(0.0020 in.)
– – –
– – –
0.02 mm
(0.0008 in.)
– – –
0.06 mm
(0.0024 in.)
0.30 mm
(0.0118 in.)
– – –
CRANKSHAFT/CRANKCASE 9-5
Specifications
Item Standard
Crankshaft #3 Main Journal Width 22.00
∼ 22.07 mm
(0.8661
∼ 0.8689 in.)
Connecting Rod Big End Bearing
Insert/Crankpin Clearance
0.020
∼ 0.044 mm
(0.0008
∼ 0.0017 in.)
Crankshaft Main Bearing
Insert/Journal Clearance
0.020
∼ 0.044 mm
(0.0008
∼ 0.0017 in.)
Pistons and Crankcase
Crankcase Warp
Crankcase Height
Cylinder Inside Diameter
– – –
238.70
∼ 239.30 mm
(9.3976
∼ 9.4212 in.)
72.00
∼ 72.03 mm
(2.8346
∼ 2.8358 in.)
Service Limit
– – –
0.07 mm
(0.0028 in.)
0.07 mm
(0.0028 in.)
0.08 mm (0.0031 in.)
238.60 mm
(9.3937 in.)
72.105 mm
(2.8388 in.) or more than
0.035 mm
(0.0014 in.) difference between any two measurements
18.05 mm (0.7106 in.)
36.06 mm (1.4197 in.)
– – –
Valve Lifter Bore Inside Diameter 18.018 mm (0.7094 in.)
Camshaft Bearing Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
– – –
71.93
∼ 71.96 mm
(2.8319
∼ 2.8331 in.)
0.06
∼ 0.08 mm
(0.0024
∼ 0.0031 in.)
0.25 mm (0.0098 in.) Oversize Oversize Piston and Rings
Piston Ring/Groove Clearance
(Top, Second and Oil Ring)
– – –
– – –
Piston Ring End Gap
(Top, Second and Oil Ring)
Piston Ring Thickness:
Top
Second
Oil
Piston Pin Bore Diameter
Piston Pin Diameter
1.445
∼ 1.465 mm
(0.0569
∼ 0.0577 in.)
1.470
∼ 1.490 mm
(0.0579
∼ 0.0587 in.)
2.970
∼ 2.990 mm
(0.1169
∼ 0.1177 in.)
– – –
– – –
0.12 mm
(0.0047 in.)
– – – less than 0.12 mm
(0.0047 in.)
0.70 mm (0.0276 in.)
– – –
– – –
– – –
18.03 mm (0.7098 in.)
17.98 mm (0.7079 in.)
9-6 CRANKSHAFT/CRANKCASE
Special Tools
Bearing Puller Adapter:
57001-136
Crankcase Splitting Tool Assembly:
57001-1098
Inside Circlip Pliers:
57001-143
Piston Pin Puller Assembly:
57001-910
Camshaft Bearing Driver:
57001-1434
Camshaft Bearing Remover:
57001-1435
Piston Ring Compressor Grip:
57001-1095
Timing Gear Cover Oil Seal Driver:
57001-1436
Piston Ring Compressor Belt, 50
∼ 67:
57001-1096
Retainer Oil Seal Driver:
57001-1437
Special Tools
Flywheel Holder:
57001-1438
CRANKSHAFT/CRANKCASE 9-7
9-8 CRANKSHAFT/CRANKCASE
Timing Gear Case
Timing Gear Case Removal
•
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Fan Belt (see Alternator Removal in the Electrical System chapter)
•
Using the flywheel holder [A], hold the crankshaft.
Special Tool - Flywheel Holder: 57001-1438
•
Remove the crankshaft pulley bolt [A].
•
Remove the crankshaft pulley [A].
Special Tools - Crankcase Splitting Tool Assembly [B]:
57001-1098
Bearing Puller Adapter [C]: 57001-136
•
Remove:
Oil Pan and Oil Strainer (see Oil Pan and Oil Strainer
Removal in the Engine Lubrication System chapter)
Timing Gear Case Cover Bolts [A]
Timing Gear Case Cover [B]
Bracket [C]
•
Temporary, install the flywheel for the crankshaft holding.
○
Using the flywheel holder [A], hold the crankshaft.
Special Tool - Flywheel Holder: 57001-1438
CRANKSHAFT/CRANKCASE 9-9
Timing Gear Case
•
Remove:
Gear Nut [A]
Gear Bolts [B]
Oil Pump Drive Gear [C]
•
Camshaft Drive Gear [D]
Position the flywheel holder to the opposite side.
•
Remove:
Idle Gear Bolts [E]
Thrust Plate [F]
Idle Gear [G]
•
Remove the idle gear shaft [A].
•
Using a suitable bearing puller [B], remove the fuel injection pump drive gear [C].
•
Remove the fuel injection pump [D] (see Fuel Injection
Pump Removal in the Fuel System chapter).
•
Remove:
Camshaft Retainer Bolts [A]
Camshaft Retainer [B]
Timing Gear Case Bolts [C]
Timing Gear Case [D]
•
Remove the oil pump outer rotor [A].
Timing Gear Case Installation
•
Clean and lubricate the oil pump outer rotor [A] with engine oil.
•
Install the oil pump outer rotor with the punch mark [B] facing inside.
9-10 CRANKSHAFT/CRANKCASE
Timing Gear Case
•
Install:
Dowel Pins [A]
New Timing Gear Case Gasket [B]
Timing Gear Case
○
Rotate the oil pump shaft to engage oil pump rotors.
•
Install the camshaft retainer [A].
•
Tighten:
Torque - Camshaft Retainer Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Timing Gear Case Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
28 mm (1.10 in.) [B]
18 mm (0.71 in.) [C]
16 mm (0.63 in.) [D]
•
Install the fuel injection pump temporarily.
•
Align the marks [A] on the injection pump and the timing gear case.
•
Install:
Fuel Injection Pump Drive Gear and Nut [A]
Camshaft Drive Gear and Bolt
○
Face the timing marks [B] on the gears upward.
•
Install the idle gear shaft [C] with the arrow [D] facing the engine top.
•
Position the crankshaft key [E] upward (top position).
•
Install the idle gear so that the timing marks on the gears are positioned as shown in the figure.
[1] Idle Gear (AA) — (A) Crankshaft Gear
[2] Idle Gear (C) — (CC) or (C) Fuel Injection Pump Drive
Gear
[3] Idle Gear (BB) — (B) Camshaft Drive Gear
•
Install the oil pump drive gear [A] and bolt.
CRANKSHAFT/CRANKCASE 9-11
Timing Gear Case
•
Temporarily install the flywheel [A] to hold the crankshaft.
○
Using the flywheel holder [B] angled toward the rear of the engine, hold the crankshaft.
Special Tool - Flywheel Holder: 57001-1438
•
Install the thrust plate [A].
•
Tighten:
Torque - Idle Gear Bolts [B]: 25 N·m (2.5 kgf·m, 18 ft·lb)
•
Position the flywheel holder to the forward side of the engine.
•
Tighten:
Torque - Fuel Injection Pump Drive Gear Nut [C]: 64 N·m
(6.5 kgf·m, 47 ft·lb)
Camshaft Drive Gear Bolt [D]: 43 N·m (4.4 kgf·m,
32 ft·lb)
Oil Pump Drive Gear Bolt [E]: 20 N·m (2.0 kgf·m,
15 ft·lb)
•
Install:
New Timing Gear Case Cover Gasket
Dowel Pins [F]
•
Confirm the small hole in the oil nozzle [A] faces the engagement of the idle gear and camshaft drive gear.
•
Tighten:
Torque - Oil Nozzle: 14 N·m (1.4 kgf·m, 10 ft·lb)
•
Install:
Timing Gear Case Cover
Bracket [A]
•
Tighten:
Torque - Timing Gear Case Cover Bolts: 7.8 N·m (0.80
kgf·m, 69 in·lb)
55 mm (2.17 in.) [B]
45 mm (1.77 in.) [C]
30 mm (1.18 in.) [D]
9-12 CRANKSHAFT/CRANKCASE
Timing Gear Case
•
Position the flywheel holder [A] back to the rear side of the engine as shown in the figure.
Special Tool - Flywheel Holder: 57001-1438
•
Wipe off the excessive oil stuck on the tapered areas of the pulley and its engaging area with a ragged cloth be-
• fore installation.
Install the crankshaft pulley [A] and bolt.
○
Fit the hole [B] in the crankshaft pulley on the pin [C] in the crankshaft gear.
•
Apply thin coat of engine oil to the threads of tightening bolt. Do not apply excessive oil to its threads.
•
Tighten:
Torque - Crankshaft Pulley Bolt: 98 N·m (10.0 kgf·m, 72.3
•
ft·lb)
Install the removed parts (see appropriate chapters).
•
Adjust the fuel injection pump timing (see Fuel Injection
Pump Timing Inspection in the Fuel System chapter)
Timing Gear Case Cover Oil Seal Replacement
•
Remove:
Timing Gear Case Cover (see Timing Gear Case Removal)
Oil Seal [A]
•
•
Replace the oil seal with new one.
Apply grease to the new oil seal.
•
Press in the oil seal with the manufacturer’s marks facing out.
Special Tool - Timing Gear Cover Oil Seal Driver [A]: 57001
-1436
CRANKSHAFT/CRANKCASE 9-13
Timing Gear Case
•
Timing Gear Inspection
Inspect the timing gears using the following sequence.
•
Check the timing gear backlash between the idle gear [A] and crankshaft gear [B].
•
Remove:
Camshaft Drive Gear (see Timing Gear Case Removal)
Fuel Injection Pump Drive Gear (see Timing Gear Case
Removal)
Oil Pump Drive Gear (see Timing Gear Case Removal)
○
Set the tip of the dial gauge [C] on the idle gear tooth.
○
Hold the crankshaft.
○
Move the idle gear back and forth noting indicator reading.
Timing Gear Backlash
Service Limit: 0.2 mm (0.008 in.)
If the backlash exceeds the service limit, check the idle gear bearing and shaft for wear.
Idle Gear Inside Diameter [A]
Service Limit: 34.17 mm (1.3453 in.)
Idle Gear Shaft Outside Diameter [B]
Service Limit: 33.91 mm (1.3350 in.)
If the idle gear bearing and shaft are within the service limit, replace the idle gear and recheck the backlash.
If the backlash exceeds the service limit with a new idle gear, crankshaft gear is worn.
If the crankshaft gear is worn, replace the crankshaft.
•
Check the timing gear backlash between the camshaft drive gear [A] and idle gear [B].
○
Set the tip of the dial gauge [C] on the camshaft drive gear tooth.
○
Hold the idle gear.
○
Move the camshaft drive gear back and forth noting indicator reading.
Timing Gear Backlash
Service Limit: 0.2 mm (0.008 in.)
If the backlash exceeds the service limit, replace the camshaft drive gear.
•
Check the timing gear backlash between the fuel injection pump drive gear [A] and idle gear [B].
○
Set the tip of the dial gauge [C] on the fuel injection pump drive gear tooth.
○
Hold the idle gear.
○
Move the fuel injection pump drive gear back and forth noting indicator reading.
Timing Gear Backlash
Service Limit: 0.2 mm (0.008 in.)
If the backlash exceeds the service limit, replace the fuel injection pump drive gear.
9-14 CRANKSHAFT/CRANKCASE
Timing Gear Case
•
Visually inspect the oil pump drive gear teeth [A] for wear and damage.
If the teeth are damaged or worn, replace the oil pump drive gear.
CRANKSHAFT/CRANKCASE 9-15
Camshaft
Camshaft Removal
•
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter)
Valve Lifters (see Valve Lifter Removal in the Engine Top
End chapter)
Oil Pan (see Oil Pan and Oil Strainer Removal in the
Engine Lubrication System chapter)
Timing Gear Case Cover (see Timing Gear Case Removal)
•
Temporarily, install the flywheel to hold the crankshaft.
•
Using the flywheel holder [A] angled toward the rear of the engine, hold the crankshaft.
Special Tool - Flywheel Holder: 57001-1438
•
Remove:
Camshaft Drive Gear Bolt [A]
Camshaft Drive Gear [B]
○
Mark the positions [A] of the camshaft drive gear [B] and idle gear [C] so that the camshaft drive gear can be installed later in the same position.
○
Do not turn the idle gear while the camshaft drive gear is removed.
9-16 CRANKSHAFT/CRANKCASE
Camshaft
•
Remove:
Camshaft Retainer Bolts [A]
Camshaft Retainer [B]
Camshaft [C]
○
Use care when removing the camshaft to prevent damaging the cam bearings, journals and lobes.
•
Camshaft Installation
Apply engine oil to all cam parts and journals.
•
Install the camshaft [A].
○
Take care when installing the camshaft to prevent damaging the cam bearings, journals and lobes.
•
Install:
Camshaft Retainer
Camshaft Retainer Bolts
Torque - Camshaft Retainer Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•
Install the camshaft drive gear [A].
○
Fit the groove [B] in the camshaft drive gear onto the key on the camshaft.
○
Align the marks [C] on the camshaft drive gear and idle gear marked when removing.
○
If the idle gear is turned, set the timing gears to the original positions (see Timing Gear Case Installation).
•
Move the flywheel holder [A] to the forward side of the engine to hold the crankshaft.
Special Tool - Flywheel Holder: 57001-1438
•
Tighten:
Torque - Camshaft Drive Gear Bolt [A]: 43 N·m (4.4 kgf·m,
32 ft·lb)
•
Install the removed parts (see appropriate chapters).
CRANKSHAFT/CRANKCASE 9-17
Camshaft
Camshaft Inspection
•
Measure the overall height [A] of each cam.
If any cam has worn past the service limit, replace the camshaft.
Cam Height
Standard:
Inlet
Exhaust
Service Limit:
Inlet
Exhaust
30.065
∼ 30.135 mm (1.1837 ∼ 1.1864 in.)
30.065
∼ 30.135 mm (1.1837 ∼ 1.1864 in.)
29.965 mm (1.1797 in.)
29.965 mm (1.1797 in.)
•
Measure the diameter of the camshaft journals.
If any journals has worn past the service limit, replace the camshaft.
Camshaft Journal Diameter
Standard:
Right Side [A]
Center [B]
Left Side [C]
35.959
∼ 35.975 mm
(1.4157
∼ 1.4163 in.)
35.910
∼ 35.955 mm
(1.4138
∼ 1.4155 in.)
35.910
∼ 35.955 mm
(1.4138
∼ 1.4155 in.)
Service Limit:
Right Side [A]
Center [B]
Left Side [C]
35.89 mm (1.413 in.)
35.84 mm (1.411 in.)
35.84 mm (1.411 in.)
•
Measure the camshaft runout.
If the measurement exceeds the service limit, replace the camshaft.
Camshaft Runout
Service Limit: 0.03 mm (0.0012 in.)
9-18 CRANKSHAFT/CRANKCASE
Crankshaft and Connecting Rods
Connecting Rod Removal
•
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter)
Valve Lifters (see Valve Lifter Removal in the Engine Top
End chapter)
Oil Pan (see Oil Pan and Oil Strainer Removal in the
Engine Lubrication System chapter)
•
Remove the carbon to prevent damaging the piston rings or piston.
NOTE
○
Number the connecting rod/piston assemblies before removing.
•
Remove:
Connecting Rod Cap Nuts [A]
Connecting Rod Cap [B]
•
Push the connecting rod end into the cylinder, and pull the piston and connecting rod out of the cylinder.
•
Reassemble the connecting rod cap to the connecting rod to prevent interchanging components.
•
Connecting Rod Installation
Install the connecting rod bearing inserts.
○
Be sure tang [A] on the bearing inserts are seated in the notches in the connecting rod and cap.
•
Install a piece of vinyl tubing [B] over each connecting rod threads to prevent damage to the threads or crankpin when installing the connecting rod.
•
Apply engine oil to the following parts.
Cylinder Bores
Pistons and Piston Rings
Bearing Inserts and Crankpins
•
Rotate the crankshaft so that the crankpin is at bottom of the stroke.
CRANKSHAFT/CRANKCASE 9-19
Crankshaft and Connecting Rods
•
Insert the piston and connecting rod with the arrow [A] on the piston facing right side (timing gears side).
○
Using the piston ring compressor grip [B] and the belt [C], lightly tap the top of the piston with a plastic mallet to insert the piston and connecting rod into the cylinder.
Special Tools - Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt, 50
∼ 67:
57001-1096
•
Apply engine oil to the threads of the connecting rod bolt.
•
Install the connecting rod caps with ID mark [A] facing right side (timing gears side).
•
Tighten:
Torque - Connecting Rod Cap Nuts: 36 N·m (3.7 kgf·m, 27 ft·lb)
○
After tightening the cap nuts, make sure the crankshaft rotates freely.
Crankshaft Removal
•
Remove:
Camshaft (see Camshaft Removal)
Timing Gear Case (see Timing Gear Case Removal)
Connecting Rods (see Connecting Rod Removal)
Oil Seal Retainer Bolts [A]
Oil Seal Retainer [B] and Gasket
•
Remove:
Crankshaft Main Bearing Cap Bolts [A]
Crankshaft Main Bearing Caps [B]
Crankshaft [C]
Thrust Washers (#3 Main Bearing)
•
Remove the upper main bearing inserts from saddles and place with the respective bearing caps.
Crankshaft Installation
•
Install the upper main bearing inserts in the crankcase.
NOTE
○
Upper main bearing inserts have an oil groove [A] and oil hole [B].
○
Be sure the bearing inserts are seated in the saddles, and the tangs in the bearing inserts are aligned with the notches in the saddles.
9-20 CRANKSHAFT/CRANKCASE
Crankshaft and Connecting Rods
•
Install the lower main bearing inserts [A] in the bearing caps [B].
○
Be sure the bearing inserts are seated in the bearing caps, and the tangs [C] in the bearing inserts are aligned with the notches [D] in the bearing caps.
•
Apply engine oil to the main bearing inserts.
•
Install the thrust washers [A] at #3 main bearing with grooves [B] facing out.
•
Install the crankshaft with the gear facing the right side
(timing gears side).
○
Take care not to damage the journals or bearing inserts.
•
Apply engine oil to the crankshaft main journals.
•
Install the main bearing caps in their respective positions with the arrows [A] facing the right side (timing gear side).
•
Tighten the cap bolts following the tightening sequence [1
∼ 4].
Torque - Crankshaft Main Bearing Cap Bolts: 59 N·m (6.0
kgf·m, 44 ft·lb)
○
After tightening the cap bolts, make sure the crankshaft rotates freely.
•
Install:
New Oil Seal Retainer Gasket [A]
Dowel Pins [B]
Oil Seal Retainer
•
Tighten:
Torque - Oil Seal Retainer Bolts: 5.4 N·m (0.55 kgf·m, 48 in·lb)
•
Connecting Rod Big End Side Clearance
Measure connecting rod big end side clearance.
○
Insert a thickness gauge between the connecting rod big end [A] and either crank web [B] to determine clearance.
If the clearance exceeds the service limit, replace the connecting rod with a new one and then check clearance again. If the clearance is too large after connecting rod replacement, the crankshaft also must be replaced.
Connecting Rod Big End Side Clearance
Standard: 0.15
∼ 0.28 mm (0.0059 ∼ 0.0110 in.)
Service Limit: 0.3 mm (0.0118 in.)
CRANKSHAFT/CRANKCASE 9-21
Crankshaft and Connecting Rods
Connecting Rod Inspection
•
Measure the inside diameter [A] of the connecting rod small end.
If the connecting rod small end bore has worn past the service limit, replace the connecting rod.
Connecting Rod Small End
Service Limit
Inside Diameter: 18.03 mm (0.7098 in.)
•
Measure the inside diameter [A] of the connecting rod big end.
○
With bearings removed, install the connecting rod cap.
•
Tighten:
Torque - Connecting Rod Cap Nuts: 36 N·m (3.7 kgf·m, 27 ft·lb)
If the connecting rod big end out of round exceeds the service limit, replace the connecting rod.
Connecting Rod Big End
Service Limit
Out of Round: 0.02 mm (0.0008 in.)
•
Check for a bent or twisted connecting rod.
NOTE
○
The thrust faces must be free of any burrs or nicks, or the connecting rod will not lay flat on a surface plate.
○
Put the connecting rod on a surface plate. Any distortion will be evident by a rocking motion.
If a 0.05 mm (0.0020 in.) thickness gauge can be inserted at the connecting rod small end, replace the connecting rod.
Connecting Rod Thrust Faces
Service Limit
Distortion: 0.05 mm (0.0020 in.)
Crankshaft Inspection
•
Visually inspect the crankshaft main journals and crankpins for grooves or signs of scoring.
If any damage is found, the crankshaft must be re-ground or replaced.
9-22 CRANKSHAFT/CRANKCASE
Crankshaft and Connecting Rods
•
Check the crankshaft main journals and crankpins for wear and taper.
Crankshaft Main Journal Diameter [A]
Standard: 41.976
∼ 42.000 mm (1.6526 ∼ 1.6535 in.)
Crankshaft Crankpin Diameter [B]
Standard: 36.976
∼ 37.000 mm (1.4557 ∼ 1.4567 in.)
Crankshaft Out of Round and Taper
Service Limit: 0.02 mm (0.0008 in.)
If the crankshaft main journals are not within specification, the crankshaft may be re-ground and undersize bearing inserts installed.
Undersize Crankshaft Main Bearing Inserts
0.25 mm (0.0098 in.) Undersize
•
The final finishing dimensions should be as shown in the table.
Finishing Dimensional Specifications
[A] 41.726
∼ 41.750 mm (1.6428 ∼ 1.6437 in.)
[B]
36.726
∼ 36.750 mm (1.4459 ∼ 1.4468 in.)
[C] R 2.5 mm (0.0984 in.)
[D] R 2.1 mm (0.0827 in.)
•
Measure the crankshaft runout at #3 main journal.
If the measurement exceeds the service limit, replace the crankshaft.
Crankshaft #3 Main Journal Runout
Service Limit: 0.06 mm (0.0024 in.)
•
Visually inspect the crankshaft gear teeth [A].
•
Do the timing gear inspection procedure (see Timing Gear
Inspection).
If the crankshaft gear teeth are damaged or worn, replace the crankshaft.
CRANKSHAFT/CRANKCASE 9-23
Crankshaft and Connecting Rods
Crankshaft Side Clearance
•
Insert a thickness gauge [A] between the thrust washer and the crank web at the #3 main journal to determine clearance.
Crankshaft Side Clearance
Standard: 0.02
∼ 0.24 mm (0.0008 ∼ 0.0094 in.)
Service Limit: 0.30 mm (0.0118 in.)
If the clearance exceeds the service limit, the crankshaft may be re-ground and oversize thrust washers installed.
Oversize Thrust Washers
0.12 mm (0.0047 in.) Oversize
•
The final finishing dimensions should be as shown in the table.
Finishing Dimensional Specifications
[A] 22.25
∼ 22.32 mm (0.8760 ∼ 0.8787 in.)
[B] R 2.5 mm (0.0984 in.)
Crankshaft #3 Main Journal Width
Standard: 22.00
∼ 22.07 mm (0.8661 ∼ 0.8689 in.)
Connecting Rod Big End Bearing Insert/Crankpin
Wear
•
Using plastigage (press gauge) [A], measure the bearing insert/crankpin clearance.
NOTE
○
Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation).
○
Do not move the connecting rod and crankshaft during clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Standard: 0.020
∼ 0.044 mm (0.0008 ∼ 0.0017 in.)
Service Limit: 0.07 mm (0.0028 in.)
If the clearance exceeds the service limit, replace the bearing insert.
•
Repeat the procedure for the other connecting rods.
9-24 CRANKSHAFT/CRANKCASE
Crankshaft and Connecting Rods
Crankshaft Main Bearing Insert/Journal Wear
•
Using plastigage (press gauge) [A], measure the bearing insert/journal clearance.
NOTE
○
Tighten the crankshaft main bearing cap bolts to the specified torque (see Crankshaft Installation).
○
Do not turn the crankshaft during clearance measurement.
Crankshaft Main Bearing Insert/Journal Clearance
Standard: 0.020
∼ 0.044 mm (0.0008 ∼ 0.0017 in.)
Service Limit: 0.07 mm (0.0028 in.)
If the clearance exceeds the service limit, replace the bearing insert.
•
Repeat the procedure for the other main bearings.
CRANKSHAFT/CRANKCASE 9-25
End Plate
End Plate Removal
•
Remove:
Torque Converter Case (see Torque Converter Case Removal in the Converter System chapter)
Stud Bolt [A]
•
Using the flywheel holder [A], hold the flywheel.
Special Tool - Flywheel Holder: 57001-1438
•
Remove:
Flywheel Mounting Bolts [B]
Coupling [C]
Flywheel [D]
•
Remove:
Bolts [A]
Engine Mount Stay [B]
Bolts [C]
Oil Level Gauge Pipe [D]
Bolt [E]
•
Remove:
End Plate Seal Cover [A]
End Plate Bolts [B]
Plate [C]
Starter Motor Mounting Bolts [D]
End Plate [E]
End Plate Installation
•
Remove the old sealant, and clean around the oil seal retainer and crankshaft end.
•
Apply liquid gasket [A] to the mating surface as shown in the figure.
Sealant - Three Bond: 1207F
When the starter motor install, refer to the Starter Motor
•
Installation in the Electrical System chapter.
Install the end plate.
•
Tighten:
Torque - End Plate Bolts: 39 N·m (4.0 kgf·m, 29 ft·lb)
9-26 CRANKSHAFT/CRANKCASE
End Plate
•
Apply liquid gasket [A] to the mating surface as shown in the figure.
Sealant - Three Bond: 1207F
•
Install the flywheel [A] and coupling.
•
Apply a non-permanent locking agent to the threads of the flywheel mounting bolts.
•
Using the flywheel holder [B], hold the flywheel.
Special Tool - Flywheel Holder: 57001-1438
•
Tighten the flywheel mounting bolts following the tightening sequence as shown in the figure.
Torque - Flywheel Mounting Bolts:
First 32 N·m (3.3 kgf·m, 24 ft·lb)
Final 44 N·m (4.5 kgf·m, 32 ft·lb)
•
Install the removed parts (see appropriate chapters).
Oil Seal Retainer
Oil Seal Replacement
•
Remove:
Oil Seal Retainer [A] (see Crankshaft Removal)
Oil Seal [B]
CRANKSHAFT/CRANKCASE 9-27
•
•
Replace the oil seal with new one.
Apply engine oil to the outside of the oil seal.
•
Press in a new oil seal so that the seal surface is flush with the end of the hole.
Special Tool - Retainer Oil Seal Driver [A]: 57001-1437
○
Apply high-temperature grease to the oil seal lips.
9-28 CRANKSHAFT/CRANKCASE
Pistons and Crankcase
Piston Removal
•
Remove:
Connecting Rod (see Connecting Rod Removal)
Snap Rings [A]
Special Tool - Inside Circlip Pliers: 57001-143
•
Remove the piston pin.
Special Tool - Piston Pin Puller Assembly [A]: 57001-910
•
Remove the piston.
•
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 to the piston pin.
•
Align the arrow [A] on the piston and ID mark [B] on the connecting rod.
•
Install:
Piston Pin
New Snap Rings
Special Tool - Inside Circlip Pliers: 57001-143
•
Install the oil ring coil expander making sure the wire is completely inserted into the coil expander.
CRANKSHAFT/CRANKCASE 9-29
Pistons and Crankcase
•
Install:
Oil Ring Coil Expander
Oil Ring [A]
Second Ring [B]
Top Ring [C]
○
The second and top rings must be installed with the “T” mark [D] facing up.
•
Position each piston ring end gap as shown in the figure.
Arrow [A]
Top Ring End Gap [B]
Second Ring End Gap [C]
Oil Ring End Gap [D]
Crankcase Removal
•
Remove:
Connecting Rods (see Connecting Rod Removal)
Crankshaft (see Crankshaft Removal)
Crankcase [A]
•
Crankcase Warp
Clean the crankcase.
•
Lay a straightedge [A] across the upper surface of the crankcase at several different points, and measure the warp by inserting a thickness gauge [B] between the straightedge and the crankcase.
Crankcase Warp
Service Limit: 0.08 mm (0.0031 in.)
If the warp exceeds the service limit, the crankcase may be resurfaced to the service limit of the crankcase height
[A].
Crankcase Height
Standard: 238.70
∼ 239.30 mm (9.3976 ∼ 9.4212 in.)
Service Limit: 238.60 mm (9.3937 in.)
If the height is less than the service limit, replace the crankcase.
9-30 CRANKSHAFT/CRANKCASE
Pistons and Crankcase
Crankcase Wear
Cylinder Bore
•
Take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure.
If any of the measurements exceeds the service limit, the cylinder will have to be bored to oversize and then honed.
10 mm (0.39 in.) [A]
45 mm (1.77 in.) [B]
20 mm (0.79 in.) [C]
Cylinder Inside Diameter
Standard: 72.00
∼ 72.03 mm (2.8346 ∼ 2.8358 in.)
Service Limit: 72.105 mm (2.8388 in.) or more than
0.035 mm (0.0014 in.) difference between any two measurements
Valve Lifter Bore
Valve Lifter Bore Inside Diameter
Standard: 18.018 mm (0.7094 in.)
Service Limit: 18.05 mm (0.7106 in.)
Camshaft Bearing
Camshaft Bearing Inside Diameter
Service Limit: 36.06 mm (1.4197 in.)
If the diameter exceeds the service limit, replace the camshaft bearing.
Piston Diameter
•
Measure the piston diameter [A] at the point shown with a micrometer.
Piston Diameter
Standard: 71.93
∼ 71.96 mm (2.8319 ∼ 2.8331 in.)
NOTE
○
If the cylinder has been bored oversize, use the oversize piston diameter.
CRANKSHAFT/CRANKCASE 9-31
Pistons and Crankcase
Piston/Cylinder Clearance
•
Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard: 0.06
∼ 0.08 mm (0.0024 ∼ 0.0031 in.)
Service Limit: 0.12 mm (0.0047 in.)
If the piston/cylinder clearance is greater than the service limit, and the cylinder inside diameter is not more than the service limit, replace the piston.
If only a piston is replaced, the clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid piston seizure.
Cylinder Boring, Honing
When boring and honing a cylinder, note the following.
○
Oversize pistons require oversize rings.
Oversize Piston and Rings
0.25 mm (0.0098 in.) Oversize
○
Before boring a cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the specifications, determine the rebore diameter. However, if the amount of boring necessary would increase the inside diameter by more than
0.25 mm (0.0098 in.), the crankcase must be replaced.
○
Cylinder inside diameter must not vary more than 0.01
mm (0.00039 in.) at any point.
○
Be wary of measurements taken immediately after boring since the heat affects cylinder diameter.
○
In the case of a rebored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm (0.0039 in.) and the service limit for the piston is the oversize piston original diameter minus 0.15 mm (0.0059 in.). If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder.
Camshaft Bearing Replacement
•
Remove the timing gear case (see Timing Gear Case Removal).
•
Using the camshaft bearing remover [A], remove the camshaft bearing.
Special Tool - Camshaft Bearing Remover: 57001-1435
9-32 CRANKSHAFT/CRANKCASE
Pistons and Crankcase
•
Install the new camshaft bearing [A].
○
Face the notch [B] in the bearing to the outside, and align the oil holes [C] in the bearing and crankcase.
•
Using the camshaft bearing driver [A], install the camshaft bearing.
Special Tool - Camshaft Bearing Driver: 57001-1434
Camshaft Plug Replacement
•
Remove:
Timing Gear Case (see Timing Gear Case Removal)
Camshaft Plug [A]
○
Use a wooden dowel or brass rod to prevent damage to the camshaft bearing.
•
Using the camshaft bearing driver [A], install a new camshaft plug.
Special Tool - Camshaft Bearing Driver: 57001-1434
Piston Ring and Ring Groove Wear
•
Check for uneven groove wear by inspecting the ring seating.
The rings should fit perfectly parallel to the groove surfaces. If not, replace the piston and all the piston rings.
•
With new piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.
Piston Ring/Groove Clearance (Top, Second and Oil Ring)
Service Limit: less than 0.12 mm (0.0047 in.)
If the piston ring/groove clearance is greater than the service limit, replace the piston.
CRANKSHAFT/CRANKCASE 9-33
Pistons and Crankcase
•
Piston Ring End Gap
Clean the carbon from the ends of the rings.
•
Place the piston ring inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low.
•
Measure the gap between the ends of the ring with a thickness gauge.
Piston Ring End Gap (Top, Second and Oil Ring)
Service Limit: 0.70 mm (0.0276 in.)
If the gap is wider than the service limit, the ring is overworn and must be replaced.
NOTE
○
When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.
•
Piston Ring Thickness
Measure the piston ring thickness [A].
○
Use a micrometer to measure at several points around the ring.
Piston Ring Thickness
Standard:
Top
Second
Oil
1.445
∼ 1.465 mm (0.0569 ∼ 0.0577 in.)
1.470
∼ 1.490 mm (0.0579 ∼ 0.0587 in.)
2.970
∼ 2.990 mm (0.1169 ∼ 0.1177 in.)
Piston and Piston Pin Wear
•
Measure the inside diameter of the piston pin bore.
If the inside diameter exceeds the service limit, replace the piston.
Piston Pin Bore Diameter
Service Limit: 18.03 mm (0.7098 in.)
•
Measure the outside diameter of the piston pin.
If the outside diameter is less than the service limit, replace the piston pin.
Piston Pin Diameter
Service Limit: 17.98 mm (0.7079 in.)
TRANSMISSION 10-1
Transmission
Table of Contents
10
10-2 TRANSMISSION
Exploded View
Exploded View
1. 2WD/4WD Shift Cable
2. Differential Shift Cable
3. White Tape
G: Apply grease.
R: Replacement Parts
TRANSMISSION 10-3
10-4 TRANSMISSION
Exploded View
Exploded View
No.
Fastener
1 Differential Gear Housing Bolts
2 Shift Arm Positioning Bolt
3 Shift Shaft Stop Bolts
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
TO: Apply transmission oil.
TRANSMISSION 10-5
N·m
57
37
7.8
Torque kgf·m
5.8
3.8
0.80
ft·lb
42
27
69 in·lb
Remarks
L
10-6 TRANSMISSION
Exploded View
TRANSMISSION 10-7
Exploded View
No.
Fastener
1 Bearing Holder
2 Hi/Low Gear Case Bolts
3 Neutral Switch
4 Transmission Case Bolts
5 Transmission Case Mounting Nuts
6 Transmission Oil Drain Plug
Torque
N·m kgf·m
118 12.0
20
15
8.8
44
15
2.0
1.5
0.90
4.5
1.5
ft·lb
87.0
15
11
78 in·lb
32
11
G: Apply grease.
LG: Apply liquid gasket.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1).
R: Replacement Parts
TO: Apply transmission oil.
Remarks
MO
R
10-8 TRANSMISSION
Specifications
Type
Viscosity
Item
Transmission Oil
Standard Service Limit
Capacity
Oil Level
Hypoid gear oil
SAE 90: above 5°C (41°F) or
SAE 80: below 5°C (41°F)
2.5 L (2.6 US qt)
Between H and L level lines on dipstick
– – –
– – –
– – –
– – –
– – –
Transmission and Shift Mechanism
Shift Arm Pin Diameter
Shifter Block Inside Diameter
Shifter Block Outside Diameter
Shifter Groove Width
Drive Chain 20-Link Length
7.95
∼ 8.00 mm (0.313 ∼ 0.315 in.)
8.05
∼ 8.10 mm (0.317 ∼ 0.319 in.)
158.76
∼ 159.18 mm
(6.250
∼ 6.267 in.)
7.8 mm (0.307 in.)
8.2 mm (0.323 in.)
13.95
∼ 14.00 mm (0.549 ∼ 0.551 in.) 13.8 mm (0.543 in.)
14.0
∼ 14.2 mm (0.551 ∼ 0.559 in.)
14.3 mm (0.563 in.)
161.1 mm (6.343 in.)
Hi/Low Gears and Shift Mechanism
Shifter Block Outside Diameter
Shifter Groove Width
2WD/4WD Shift Mechanism
Shifter Block Outside Diameter
Shifter Groove Width
Differential Gears and Shift
Mechanism
Shift Arm Pin Diameter
Shifter Groove Width
13.95
14.05
13.95
14.0
8.4
9.0
∼ 14.00 mm (0.549 ∼ 0.551 in.) 13.8 mm (0.543 in.)
∼ 14.15 mm (0.553 ∼ 0.557 in.) 14.3 mm (0.563 in.)
∼ 14.00 mm (0.549 ∼ 0.551 in.) 13.8 mm (0.543 in.)
∼ 14.2 mm (0.551 ∼ 0.559 in.)
∼ 8.6 mm (0.331 ∼ 0.339 in.)
∼ 9.1 mm (0.354 ∼ 0.358 in.)
14.3 mm (0.563 in.)
8.3 mm (0.327 in.)
9.2 mm (0.362 in.)
Special Tools and Sealant
Outside Circlip Pliers:
57001-144
TRANSMISSION 10-9
Hexagon Wrench, Hex 32:
57001-1194
Liquid Gasket, TB1105B:
92104-002
Oil Seal & Bearing Remover:
57001-1058
Bearing Driver Set:
57001-1129
10-10 TRANSMISSION
Transmission Oil
NOTICE
Vehicle operation with insufficient, deteriorated or contaminated transmission oil will cause accelerated wear and may result in transmission failure.
Transmission Oil Level Inspection
NOTE
○
If the vehicle has just been used wait several minutes for all the oil to settle down.
•
Park the vehicle on level ground, and tilt up the cargo bed.
•
Unscrew the oil filler cap [A], wipe its dipstick [B] dry, and insert it into the filler opening but DO NOT SCREW IT IN.
•
Pull out the dipstick and check the oil level. The oil level should be between the upper (H) and lower (L) level lines
[C].
If the oil level is too high, remove the excess oil, using a syringe or some other suitable device, through the oil filler opening.
If the oil level is too low, add the necessary amount of oil through the oil filler opening. Use the same type and make of oil that is already in the transmission.
NOTE
○
If the transmission oil type and make are unknown, use any brand of the specified oil to top up the level in preference to running the transmission with the oil level low.
Then, at your earliest convenience, change the oil completely.
Transmission Oil Change
•
Refer to the Transmission Oil Change in the Periodic
Maintenance chapter.
Transmission Case
Transmission Case Removal
•
Drain the transmission oil (see Transmission Oil Change in the Periodic Maintenance chapter).
•
Remove:
Cargo Bed (see Cargo Bed Removal in the Frame chapter)
Propeller Shaft (see Propeller Shaft Removal in the Final
Drive chapter)
Torque Converter Case (see Torque Converter Case Removal in the Converter System chapter)
Rear Drive Shafts and Axles (see Rear Drive Shaft and
Axle Removal in the Final Drive chapter)
Muffler (see Muffler Removal in the Engine Top End chapter)
•
Remove:
Neutral Switch Terminal Lead [A]
Speed Sensor Lead Connector [B]
2WD/4WD Shift Cable Lower End [C]
Differential Shift Cable Lower End [D]
TRANSMISSION 10-11
•
Remove:
Transmission Shift Cable Lower End Lever [A]
Hi/Low Shift Cable Lower End Lever [B]
Bolts [C] and Collars
Injection Pump Cover [D]
•
Remove:
Bolts and Nuts [A]
Engine Mount Stay [B]
10-12 TRANSMISSION
Transmission Case
•
Remove:
Bolt [A]
Thick Holder [B]
Thin Holder [C]
Speedometer Cable Lower End [D]
•
Remove:
Transmission Case Mounting Bolts and Nuts [A]
Transmission Case [B]
Transmission Case Installation
•
Adjust the transmission case mounting position (see Engine Installation in the Engine Removal/Installation chapter).
•
Tighten:
Torque - Transmission Case Mounting Nuts: 44 N·m (4.5
kgf·m, 32 ft·lb)
•
Install:
Speedometer Gear [A]
Washer [B]
New O-ring [C]
Bushing [D]
Oil Seal [E]
Thick Holder [F]
Thin Holder [G]
Bolt [H]
•
Adjust:
Transmission Oil (see Transmission Oil Change in the
Periodic Maintenance chapter)
Transmission Shift Cable (see Shift Lever Position Adjustment)
Differential Shift Cable (see Differential Shift Cable Adjustment)
Hi/Low Shift Cable (see Shift Lever Position Adjustment)
2WD/4WD Shift Cable (see 2WD/4WD Shift Cable Adjustment)
Transmission Case
Transmission Case Splitting
•
Remove:
Transmission Case (see Transmission Case Removal)
Bevel Gear Case (see Bevel Gear Case Removal in the
Final Drive chapter)
Hi/Low Gear Case (see Hi/Low Gear and Shift Mechanism Removal)
Cable Bracket [A]
Bolts [B]
Left Transmission Case [C]
Transmission Case Assembly
•
Check to see that the transmission case dowel pins [A] are in place. If any one of them has been removed, replace it with a new one.
•
Apply liquid gasket to the transmission case mating surface.
•
Sealant - Liquid Gasket, TB1105B: 92104-002
Apply grease to the oil seal lips
•
Tighten:
Torque - Transmission Case Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
TRANSMISSION 10-13
10-14 TRANSMISSION
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 [A] temporarily set the shift arm
[B] in forward or reverse position as shown in the figure.
•
Put the differential shift lever [A] in “LOCK” position.
•
Turn the hi/low shift shaft lever [A] clockwise while turning the drive shafts (wheels) until the lever engages low gear.
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].
TRANSMISSION 10-15
•
Line up the punch mark [A] on the shift arm, projection
[B] on the transmission case and slit opening in the shift shaft lever [C].
•
Tighten:
Shift Shaft Lever Nut [D]
Shift Shaft Lever Clamp Bolt [E]
•
Hold the shift shaft lever [A] in the low range position turning fully clockwise, and then push the outer cable [B] lightly rearward to remove the cable free play.
•
Tighten:
Hi/Low Shift Cable Adjuster Nut [C]
Hi/Low Shift Cable Adjuster Nut [D]
•
Put the shift lever [A] in the center of right and left at “N”
(NEUTRAL) position, and hold it at the location [B].
○
Install suitable plates [C] between the shift lever and lower and upper side of the gate in order to fix the shift lever.
•
Using the shift shaft lever [A] temporarily set the shift arm
[B] in neutral position as shown in the figure.
10-16 TRANSMISSION
Transmission and Shift Mechanism
•
Screw the joint [A] of the shift shaft lever [B] fully into the transmission shift cable [C] end, and install the cable onto the bracket [D].
•
Line up the punch mark [A] on the shift arm, projection
[B] on the transmission case and slit opening in the shift shaft lever [C].
•
Tighten:
Shift Shaft Lever Nut [D]
Shift Shaft Lever Clamp Bolt [E]
•
Hold the shift shaft lever [A] in the neutral position, and then pull the outer cable [B] lightly forward to remove the cable free play.
NOTE
○
If the cable cannot be adjusted, move the slit opening in the shift shaft lever one notch to right side of the punch mark on the shift arm.
•
Tighten:
Transmission Shift Cable Adjuster Nut [C]
Transmission Shift Cable Adjuster Nut [D]
•
Install the spring [A] back onto the shift shaft lever assembly.
•
Check the shift lever position (see Shift Lever Position
Inspection).
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.
•
Check the grinding noise at the specified positions [B] and
[C].
If the position of the grinding noise is far from the specified position, adjust the shift lever position (see Shift Lever
Position Adjustment).
Shift Lever Position Adjustment
•
Loosen the hi/low shift cable adjuster nuts [A] and [B].
TRANSMISSION 10-17
•
Adjust the hi/low shift cable and set the transmission shift lever [A] in the correct position as follows.
•
The gap [B] between the shift lever and panel is approximate 1.5 mm (0.06 in.).
○
When the outer cable moving forward, the shift lever moves left side.
○
When the outer cable moving rearward, the shift lever moves right side.
•
Tighten the hi/low shift cable adjuster nuts.
•
Loosen the transmission shift cable adjuster nuts [A] and
[B].
•
Adjust the transmission shift cable and set the transmission shift lever [A] in the correct position as follows.
○
When the shift lever moving to right and left, the gaps between [B] and [C] are same.
○
When the outer cable moving forward, the shift lever moves upward.
○
When the outer cable moving rearward, the shift lever moves downward.
•
Tighten the transmission shift cable adjuster nuts.
10-18 TRANSMISSION
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.
Transmission Removal
•
Remove:
Transmission Case (see Transmission Case Removal)
Hi/Low Shift Gear (see Hi/Low Gear and Shift Mechanism Removal)
Speedometer Gear (see 2WD/4WD Shift Mechanism
Removal)
•
Split the transmission case (see Transmission Case Splitting)
•
Remove:
Differential Gear Assembly (see Differential Gear Removal)
Drive Shaft [A]
Washers [B]
Drive Shaft Reverse Sprocket [C]
Drive Chains [D]
•
Remove:
Shift Arm Positioning Bolt Assembly [A]
Retaining Pin [B]
•
Lift the shift arm [C] and remove the shifter [D].
•
Remove:
Drive Shaft (Outer) [A] and Drive Shaft Forward Gear [B]
Shifter Block [C]
Shift Arm [D]
Transmission and Shift Mechanism
•
Remove the driven shaft assembly [A].
•
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 install the circlips [A] so that the opening [B] is aligned with a spline groove. To install a circlip without damage, first fit the circlip onto the shaft [C] and then expand it just enough to install. Hence, use a suitable gear to push the circlip into place.
•
Apply transmission oil to the following parts.
Drive and Driven Shafts
Forward Gears
Reverse Sprockets
Drive Chains
•
Apply grease to the following parts.
Oil Seal Lips
Shift Arm Positioning Ball and Spring
•
Install the shifter [A] so that the groove [B] is away from the forward gear [C].
•
Tighten:
Torque - Shift Arm Positioning Bolt: 37 N·m (3.8 kgf·m, 27 ft·lb)
TRANSMISSION 10-19
10-20 TRANSMISSION
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.
If they are damaged or worn excessively, replace them.
•
Replace parts worn beyond the service limit.
Shift Arm Pin Diameter [A]
Standard: 7.95
∼ 8.00 mm (0.313 ∼ 0.315 in.)
Service Limit: 7.8 mm (0.307 in.)
Shifter Block Inside Diameter [B]
Standard: 8.05
∼ 8.10 mm (0.317 ∼ 0.319 in.)
Service Limit: 8.2 mm (0.323 in.)
Shifter Block Outside Diameter [C]
Standard: 13.95
∼ 14.00 mm (0.549 ∼ 0.551 in.)
Service Limit: 13.8 mm (0.543 in.)
Shifter Groove Width [D]
Standard: 14.0
∼ 14.2 mm (0.551 ∼ 0.559 in.)
Service Limit: 14.3 mm (0.563 in.)
Drive Chain 20-Link Length [B]
Standard: 158.76
∼ 159.18 mm (6.250 ∼ 6.267 in.)
Service Limit: 161.1 mm (6.343 in.)
Force [A]
1st Pin [C]
2nd Pin [D]
21th Pin [E]
Hi/Low Gears and Shift Mechanism
Hi/Low Shift Cable Installation
•
Refer to the Transmission and Hi/Low Shift Cables Installation.
Hi/Low Shift Cable Inspection
•
With the cable disconnected at both ends, the cable should move freely within the cable housing.
If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable.
TRANSMISSION 10-21
Hi/Low Gear and Shift Mechanism Removal
•
Remove:
Bevel Gear Case (see Bevel Gear Case Removal in the
Final Drive chapter)
Hi/Low Shift Shaft Lever [A]
2WD/4WD Shift Cable Lower End [B]
Cable Bracket [C]
•
Remove:
Hi/Low Gear Case Bolts [A]
Hi/Low Gear Case [B]
•
Remove:
Washer [A]
High Gear [B]
Washer
Shifter [C]
Reduction Gear [D]
10-22 TRANSMISSION
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 transmission oil to the following parts.
Hi/Low Gears
Shifter
•
Apply grease to the oil seal lips.
•
Replace the circlip that was removed with a new one.
NOTE
○
Always install the circlip [A] so that the opening [B] is aligned with a spline groove. To install a circlip without damage, first fit the circlip onto the shaft [C] and then expand it just enough to install. Hence, use a suitable gear to push the circlip into place.
Hi/Low Gears and Shift Mechanism
•
Install the shifter [A] so that the large dogs [B] face to the low gear [C].
TRANSMISSION 10-23
•
Install:
Reduction Gear
Washer [A]
•
Install the high gear [B] so that the small gear side [C] faces shifter side.
•
Replace the hi/low gear case gasket [A] with a new one.
•
Install:
Washer [B]
Shifter [C]
•
Check to see that the hi/low gear case dowel pins [D] are in place on the transmission case.
•
Insert the shift shaft [A] in the gear case [B].
•
Touch [C] the lever [D] of the shift shaft to lib [E].
•
Fit the shift arm pins [A] into the shifter grooves [B] and install the hi/low gear case.
•
Tighten:
Torque - Hi/Low Gear Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
10-24 TRANSMISSION
Hi/Low Gears and Shift Mechanism
•
•
Install the retaining pin [A].
•
Replace the O-ring [B] with a new one.
•
Apply grease to the new O-ring and install the holder [C].
•
Tighten the bolt [D].
Check that each gear and shifter spins or slides freely on its shaft without binding after assembly.
Hi/Low Gear and Shift Mechanism Inspection
•
Visually inspect the hi/low gears, shifter, and low gear bushing [A].
If they are damaged or worn excessively, replace them.
•
Replace parts worn beyond the service limit.
Shifter Block Outside Diameter [A]
Standard: 13.95
∼ 14.00 mm (0.549 ∼ 0.551 in.)
Service Limit: 13.8 mm (0.543 in.)
Shifter Groove Width [B]
Standard: 14.05
∼ 14.15 mm (0.553 ∼ 0.557 in.)
Service Limit: 14.3 mm (0.563 in.)
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].
TRANSMISSION 10-25
•
Put the shift lever [A] in the 4WD position.
•
Turn the shift shaft lever [A] counterclockwise until the lever is stopped by engaging the shifter with the drive bevel gear shaft.
•
Screw in the upper adjuster nut [B] by hand until the inner cable [C] has no slack while holding the shift lever in the
4WD position.
•
Tighten the lower adjuster nut [D] securely.
2WD/4WD Shift Cable Lubrication
Whenever the shift cable is removed, lubricate the cable
• as follows.
Apply a thin coating of grease to the cable ends.
•
Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber.
10-26 TRANSMISSION
2WD/4WD Shift Mechanism
2WD/4WD Shift Cable Inspection
•
With the cable disconnected at both ends, the cable should move freely [A] 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.
2WD/4WD Shift Mechanism Removal
•
Remove:
Hi/Low Gear Case (see Hi/Low Gear and Shift Mechanism Removal)
Shift Shaft Stop Bolt [A] and Washer
•
Remove:
Shift Shaft Lever Mounting Nut [A]
Shift Shaft Lever [B]
Spring [C]
•
Remove:
O-ring [A]
Shift Shaft [B]
•
Remove:
Shifter [A]
Circlip [B]
Speedometer Gear [C]
Collar
Special Tool - Outside Circlip Pliers: 57001-144
2WD/4WD Shift Mechanism Installation
•
Apply transmission oil to the following parts.
Speedometer Gear
Shifter
2WD/4WD Shift Mechanism
•
Replace the circlip that was removed with a new one.
NOTE
○
Always install the circlip [A] so that the opening [B] is aligned with a spline groove. To install a circlip without damage, first fit the circlip onto the shaft [C] and then expand it just enough to install. Hence, use a suitable gear to push the circlip into place.
•
Install the collar [A].
•
Install the speedometer gear [B] so that the stepped side
[C] faces to the inside.
•
Install the new circlip.
Special Tool - Outside Circlip Pliers: 57001-144
TRANSMISSION 10-27
•
Install the shifter so that the dogs [A] face to the outside.
•
•
Insert the shift shaft [A] in the gear case.
Replace the O-ring [B] with a new one.
•
Install the new O-ring and apply molybdenum disulfide grease to it.
•
When the hi/low gear case installing, refer to the Hi/Low
Gear and Shift Mechanism Installation.
10-28 TRANSMISSION
2WD/4WD Shift Mechanism
•
Push the shift shaft [A] as shown in the figure.
•
Install:
Washer [B]
Shift Shaft Stop Bolt [C]
•
Tighten:
Torque - Shift Shaft Stop Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•
Wipe off any protruding grease.
•
Install the spring [A].
•
Turn the shift shaft [B] counterclockwise until it is stop and hold it.
•
Install the shift shaft lever [C] on the shift shaft so that the center of the lever hole aligns with the mark [D] as shown
• in the figure.
Tighten the shift shaft lever mounting nut [E].
•
Hook the spring end.
•
Check that each gear and shifter spins or slides freely on its shaft without binding after assembly.
2WD/4WD Shift Mechanism Inspection
•
Visually inspect the following parts.
Dogs on Shifter [A]
Shifter Groove [B]
Dogs on Drive Bevel Gear Shaft [C]
Shifter Block [D]
If they are damaged or worn excessively, replace them.
•
Replace parts worn beyond the service limit.
Shifter Block Outside Diameter
Standard: 13.95
∼ 14.00 mm (0.549 ∼ 0.551 in.)
Service Limit: 13.8 mm (0.543 in.)
Shifter Groove Width
Standard:
Service Limit:
14.0
∼ 14.2 mm (0.551 ∼ 0.559 in.)
14.3 mm (0.563 in.)
Differential Gears and Shift Mechanism
Differential Shift Cable Adjustment
•
Put the shift lever [A] in the UNLOCK position.
TRANSMISSION 10-29
•
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 [C] securely.
Differential Shift Cable Lubrication
Whenever the shift cable is removed, lubricate the cable
• as follows.
Apply a thin coating of grease to the cable ends.
•
Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber.
Differential Shift Cable Inspection
•
With the cable disconnected at both ends, the cable should move freely [A] 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.
Differential Shift Mechanism Removal
•
Remove:
Drive Shafts and Axles (see Rear Drive Shaft and Axle
Removal in the Final Drive chapter)
Shift Shaft Stop Bolt [A]
Shift Shaft Lever Mounting Nut [B]
Shift Shaft Lever [C]
Spring [D]
Shift Shaft and Arm [E]
10-30 TRANSMISSION
Differential Gears and Shift Mechanism
•
Differential Shift Mechanism Installation
Insert the shift shaft [A] in the gear case [B].
•
Replace the O-ring [C] with a new one.
•
Install the new O-ring and apply molybdenum disulfide grease to it.
•
Push the shift shaft [A] as shown in the figure.
•
Install:
Washer [B]
Shift Shaft Stop Bolt [C]
•
Tighten:
Torque - Shift Shaft Stop Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•
Wipe off any protruding grease.
•
•
Install the spring [A].
Turn the shift shaft [B] clockwise until stop and hold it.
•
Install the shift shaft lever [C] on the shift shaft so that the lever is position like the figure.
•
Tighten the shift shaft lever mounting nut [D].
•
Hook the spring end [E] as shown in the figure.
Differential Shift Mechanism Inspection
•
Visually inspect the following parts.
Splines on Drive Shaft [A]
Splines on Shifter [B]
Dogs [C] on Shifter
Shifter Groove [D]
•
Visually inspect the following parts
Shift Arm Pin [A]
Dogs [B] on Differential Gear Housing
If they are damaged or worn excessively, replace them.
Differential Gears and Shift Mechanism
•
Replace parts worn beyond the service limit.
Shift Arm Pin Diameter [A]
Standard: 8.4
∼ 8.6 mm (0.331 ∼ 0.339 in.)
Service Limit: 8.3 mm (0.327 in.)
Shifter Groove Width [B]
Standard: 9.0
∼ 9.1 mm (0.354 ∼ 0.358 in.)
Service Limit: 9.2 mm (0.362 in.)
Differential Gear Removal
•
Split the transmission gear case (see Transmission Gear
Case Splitting).
•
Remove the differential gear [A].
TRANSMISSION 10-31
•
Remove:
Differential Gear Housing Bolts [A]
Final Gear [B]
•
Remove:
Housing Cover [A]
Dowel Pin [B]
Side Gear [C]
Spacer [D]
•
Remove:
Dowel Pins [A]
Retaining Pin [B]
Pinion Gear Shaft [C]
Pinion Gears [D]
Spacers
Side Gear [E]
Spacer
10-32 TRANSMISSION
Differential Gears and Shift Mechanism
Differential Gear Installation
•
Apply transmission oil to the following parts.
Side Gears
Pinion Gears
•
Apply a non-permanent locking agent to the threads of the differential gear housing bolts and tighten them.
Torque - Differential Gear Housing Bolts: 57 N·m (5.8
kgf·m, 42 ft·lb)
If the backlash of the differential gears cannot keep, replace the spacers [A] to thinner spacers.
Spacers
Thickness
1.2 mm (0.047 in.)
1.0 mm (0.039 in.)
Part Number
92200-0021
92200-1044
NOTE
○
Use the spacers of the same thickness as a set.
○
Do not use the spacers of 1.2 mm (0.047 in.) and 1.0
mm (0.039 in.) thickness at the same time.
Differential Gear Inspection
•
Visually inspect the differential gears [A].
Replace the gears as a set if either gear is damaged.
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 bearing holder
[B] and remove the drive bevel gear shaft bearing.
Special Tool - Hexagon Wrench, Hex 32: 57001-1194
•
Apply molybdenum disulfide oil solution to the threads of the drive bevel gear shaft bearing holder [A].
•
Install the bearing holder so that the projections [B] face to outside.
•
Tighten:
Torque - Bearing Holder: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
•
Using a press and the bearing driver set, install the new bearings and/or new oil seals.
Special Tool - Bearing Driver Set: 57001-1129
Ball Bearing Inspection
•
Turn each bearing back and forth [A] while checking for roughness or binding.
If roughness or binding is found, replace the bearing.
•
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
•
Needle Bearing Inspection
Check the needle bearing.
○
The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.
If there is any doubt as to the condition of a needle bearing, replace it.
Oil Seal Inspection
•
Visually inspect the oil seal.
Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
TRANSMISSION 10-33
10-34 TRANSMISSION
Transmission Sectional Figure
Transmission Sectional Figure
TRANSMISSION 10-35
WHEELS/TIRES 11-1
Wheels/Tires
Table of Contents
11
11-2 WHEELS/TIRES
Exploded View
Exploded View
No.
1 Wheel Nuts
Fastener
WHEELS/TIRES 11-3
N·m
137
Torque kgf·m
14.0
ft·lb
101
Remarks
11-4 WHEELS/TIRES
Specifications
Item
Wheel Alignment
Caster
Camber
Toe-in
Wheels (Rims)
Rim Size:
Front and Rear
Tires
Standard Tire:
Front and Rear
Standard
7.5° (non-adjustable)
0.8° (non-adjustable)
0
∼ 20 mm (0 ∼ 0.79 in.) at 1G
10 × 8.5 AT
Tire Air Pressure (when Cold):
Front
Rear
Maximum Tire Air Pressure (to seat beads, when cold)
Tire Tread Depth
23 × 11.00-10
DUNLOP KT869, Tubeless
DURO DK-968, Tubeless
97 kPa (1.0 kgf/cm², 14 psi)
167 kPa (1.7 kgf/cm², 24 psi)
250 kPa (2.5 kgf/cm², 36 psi)
13.2 mm (0.52 in.)
Service Limit
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
3 mm (0.12 in.)
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 in the figure. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs.
Caster and camber are built-in and require no adjustment.
A (Rear) - B (Front) = Amount of Toe-in
(Distance A and B are measured at hub height)
•
Toe-in Adjustment
Lift the front wheels off the ground.
•
Apply a heavy coat of chalk near the center of the front tires.
•
Using a needle nose scriber, make a thin mark near the center of the chalk coating while turning the wheel.
•
Set the wheels so that the marks on the tires are at the front side and at the level of the axle height.
•
•
Ground the front wheels.
Set the steering wheel straight ahead.
•
At the level of the axle height, measure the distance between the scribed lines with a measure.
•
Move the vehicle rearward until the marks on the front tires are at the rear side and at the same level as the axle.
•
Measure the distance between the scribed lines.
•
Subtract the measurement of the front from the measurement of the rear to get the toe-in.
Toe-in of Front Wheels
Standard: 0
∼ 20 mm (0 ∼ 0.79 in.) at 1G
If the toe-in is not the specified value, perform the following procedure.
•
Loosen the locknuts [A] on each tie-rod and turn the adjusting rods [B] the same number of turns and the same direction on both sides to achieve the specified toe-in.
WHEELS/TIRES 11-5
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.
•
Tighten:
Torque - Tie-Rod End Locknuts: 44 N·m (4.5 kgf·m, 32 ft·lb)
•
Check the toe-in again.
•
Test drive the vehicle.
Wheels (Rims)
•
•
Wheel Removal
Loosen the wheel nuts [A].
○
Do not remove the wheel nuts.
•
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·m (14.0 kgf·m, 101 ft·lb)
○
Tighten the wheel nuts in a criss-cross pattern.
Wheel (Rim) Inspection
•
Examine both sides of the rim for dents [A].
If the rim is dented, replace it.
WHEELS/TIRES 11-7
If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary.
•
Wheel (Rim) Replacement
Remove the wheel (see Wheel Removal).
•
Disassemble the tire from the rim.
•
Remove the valve stem and discard it.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
Plastic Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
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 [A] the stem through the rim from the inside out until it snaps into place.
NOTICE
Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.
•
Mount the tire on the new rim.
•
Install the wheel (see Wheel Installation).
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.
NOTICE
Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire.
•
Remove the tire from the rim using a suitable commercially available tire changer.
NOTE
○
The tires cannot be removed with hand tools because they fit the rims tightly.
•
Tire Installation
Inspect the rim.
•
Check the tire for wear and damage.
•
Replace the air valve with a new one.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
•
Lubricate the tire beads and rim flanges with a soap and water solution, or water.
WARNING
Do not use any lubricant other than a water and soap solution, or water to lubricate the tire beads and rim because it may cause tire separation, and a hazardous condition may result.
•
Install the tire on the rim using a suitable commercially available tire changer.
•
Lubricate the tire beads again and center the tire on the rim.
•
Support the wheel rim [A] on a suitable stand [B] to prevent the tire from slipping off.
•
Inflate the tire until the tire beads seat on the rim.
Maximum Tire Air Pressure (to seat beads, when cold)
Front and Rear: 250 kPa (2.5 kgf/cm², 36 psi)
WARNING
Overinflating a tire can cause it to explode, causing serious injury or death. Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than maximum pressure.
WHEELS/TIRES 11-9
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, check for air leaks.
○
Apply a soap and water solution around the tire bead and check for bubbles.
•
Check the tire pressure using an air pressure gauge.
Tire Air Pressure (when Cold)
Front: 97 kPa (1.0 kgf/cm², 14 psi)
•
Rear: 167 kPa (1.7 kgf/cm², 24 psi)
Install the wheel (see Wheel Installation).
•
Wipe off the soap and water solution, or water on the tire, and dry the tire before operation.
WARNING
Water or soap solution on the tire bead can cause tire separation and an accident resulting in serious injury or death. Do not operate the vehicle until any water or soap solution applied to the bead has completely dried.
Tire Inspection
•
Refer to the Tire Wear Inspection in the Periodic Maintenance chapter.
FINAL DRIVE 12-1
Final Drive
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Front Final Gear Case .......................
Front Final Gear Case Oil Level
Inspection..................................
Change......................................
Front Final Gear Case Removal ..
Front Final Gear Case Installation
Disassembly..............................
Front Final Gear Case Assembly.
Differential Unit and Ring Gear
Disassembly..............................
Differential Unit and Ring Gear
Assembly...................................
LSD Clutch Torque Inspection .....
LSD Clutch Plate Inspection ........
Pinion Gear Unit Disassembly .....
Pinion Gear Unit Assembly ..........
Adjustment ................................
Backlash Adjustment ...................
Tooth Contact Adjustment............
Bevel Gear Inspection..................
Differential Gear Inspection .........
Inspection..................................
Ball Bearing Inspection ................
Oil Seal Inspection .......................
Bevel Gear Case ...............................
Bevel Gear Case Removal ..........
Bevel Gear Case Installation .......
Bevel Gear Case Disassembly ....
Bevel Gear Case Assembly .........
Drive Bevel Gear Removal ..........
Drive Bevel Gear Installation .......
Bevel Gear Adjustment ................
Backlash Adjustment ...................
Tooth Contact Adjustment............
Bevel Gear Inspection..................
Ball Bearing Inspection ................
Oil Seal Inspection .......................
Damper Inspection.......................
Propeller Shafts .................................
Propeller Shaft Removal ..............
Propeller Shaft Installation ...........
Propeller Shaft Bearing Housing
Removal ....................................
Propeller Shaft Bearing Housing
Installation .................................
Propeller Shaft Inspection............
Drive Shaft and Axles ........................
Front Axle Removal .....................
Front Axle Installation ..................
Removal ....................................
Installation .................................
Drive Shaft and Axle Inspection...
Dust Boot Inspection....................
Replacement .............................
Ball Bearing Inspection ................
Grease Seal Inspection................
12
12-2 FINAL DRIVE
Exploded View
FINAL DRIVE 12-3
Exploded View
No.
Fastener
1 Differential Case Cap Bolts
2 Front Axle Cap Bolts
3 Gear Case Bracket Bolts
4 Gear Case Mounting Nuts
5 Oil Drain Plug
6 Oil Filler Cap
7 Pinion Gear Bearing Housing Nuts
8 Pinion Gear Slotted Nut
9 Ring Gear Bolts
10 Ring Gear Cover Bolts (M10)
11 Ring Gear Cover Bolts (M8)
Torque
N·m kgf·m
32 3.3
8.8
44
44
20
29
25
118
82
47
25
0.90
4.5
4.5
2.0
3.0
2.5
12.0
8.4
4.8
2.5
ft·lb
24
78 in·lb
32
32
15
21
18
87.0
61
35
18
G: Apply grease.
HO: Apply hypoid gear oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
Remarks
L
R
MO
L
12-4 FINAL DRIVE
Exploded View
FINAL DRIVE 12-5
Exploded View
No.
Fastener
1 Bearing Holder
2 Bevel Gear Case Bolts
3 Bevel Gear Case Holder Nuts
4 Drive Gear Nut
Torque
N·m kgf·m
118 12.0
22
25
118
2.2
2.5
12.0
ft·lb
87.0
16
18
87.0
5 Drive Shaft Cap Bolts
6 Driven Gear Shaft Nut
7 Grease Nipple
8 Housing Locknut
20
108
2.3
118
2.0
11.0
0.23
12.0
15
79.7
20 in·lb
87.0
9 Propeller Shaft Bearing Housing Cover Bolts
10 Speed Sensor Bolt
3.4
8.8
0.35
0.90
30 in·lb
78 in·lb
11. KAF950G9
∼ GC/HA
12. EUR Model
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
TO: Apply transmission oil.
Remarks
L
MO
L
G
L
12-6 FINAL DRIVE
Specifications
Item
Front Final Gear Case
Gear Case Oil:
Type
Standard
Viscosity
Capacity
Hypoid gear oil for LSD
(Limited Slip Differential gears)
SAE 140 (GL-5) or SAE 90 (GL-6)
0.4 L (0.4 US qt)
Oil Level
LSD Clutch Torque
Filler opening level
7.8
∼ 13 N·m
Outside Friction Plate
Thickness
(0.8
∼ 1.3 kgf·m, 69 ∼ 115 in·lb)
2.3
∼ 2.4 mm (0.091 ∼ 0.094 in.)
Inside Friction Plate Thickness 2.7
∼ 2.8 mm (0.106 ∼ 0.110 in.)
Pinion Gear Bearing Preload 1.5
∼ 3.0 N (0.15 ∼ 0.31 kgf, 0.34 ∼ 0.67 lb)
Pinion Gear Bearing Preload
Torque
Bevel Gear Backlash
0.3
∼ 0.6 N·m (0.03 ∼ 0.06 kgf·m, 2.6 ∼ 5.2
in·lb)
0.14
∼ 0.69 mm (0.0055 ∼ 0.0271 in.)
(at ditch portion of the pinion gear slotted nut)
Bevel Gear Case
Bevel Gear Backlash 0.07
∼ 0.15 mm (0.0028 ∼ 0.0059 in.)
(at middle of gear dog side on drive gear shaft)
Service Limit
– – –
– – –
– – –
– – –
– – –
2.1 mm (0.083 in.)
2.4 mm (0.094 in.)
– – –
– – –
– – –
– – –
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
FINAL DRIVE 12-7
Pinion Gear Holder, m1.0:
57001-1285
Hexagon Wrench, Hex 40:
57001-1324
Socket Wrench:
57001-1363
Transmission Gear Holder:
57001-1676
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 Nuts and Bolts [A]
Front Final Gear Case Skid Plate [B]
•
Remove the filler cap [A].
NOTICE
Be careful not to allow any dirt or foreign materials to enter the gear case.
•
Check the oil level. The oil level should come to the bottom of the filler opening [A].
If it is insufficient, first check the front final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case.
•
Be sure the O-ring [B] is in place, and tighten the filler cap.
Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 21 ft·lb)
•
Replace the front final gear case skid plate nuts with new ones and install the skid plate.
Front Final Gear Case Oil Change
•
Refer to the Front Final Gear Case Oil Change in the Periodic Maintenance chapter.
Front Final Gear Case
Front Final Gear Case Removal
•
Drain the front final gear case oil (see Front Final Gear
Case Oil Change in the Periodic Maintenance chapter).
•
Remove:
Radiator (see Radiator Removal in the Cooling System chapter)
Propeller Shafts (see Propeller Shaft Removal)
Front Axles (see Front Axle Removal)
Vent Hose [A]
Front Final Gear Case Mounting Bolts and Nuts [B]
Collar [C]
•
Remove:
Front Final Gear Case Bracket Bolts [A]
Front Final Gear Case Bracket [B]
FINAL DRIVE 12-9
•
Remove the front final gear case [A] upward, together with the mounting bolt [B].
•
Front Final Gear Case Installation
•
Run the gear case vent hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
•
Replace the gear case mounting nuts with new ones.
Tighten:
Torque - Gear Case Bracket Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)
Gear Case Mounting Nuts: 44 N·m (4.5 kgf·m, 32 ft·lb)
•
Adjust the front final gear case oil (see Front Final Gear
Case Oil Change in the Periodic Maintenance chapter).
12-10 FINAL DRIVE
Front Final Gear Case
Front Final Gear Case Disassembly
•
Remove:
Front Final Gear Case (see Front Final Gear Case Removal)
Bearing Housing Nuts [A]
Pinion Gear Unit [B]
•
Remove the spacers [A] on both sides.
•
Remove the ring gear cover bolts, starting with the smaller bolts [B].
Larger Bolts [C]
Ring Gear Cover [D]
•
Remove the ring gear [A] together with the differential unit
[B].
Front Final Gear Case Assembly
•
Visually check the pinion gear and ring gear for scoring, chipping, or other damage.
Replace the bevel gears as a set if either gear is damaged since they are lapped as a set in the factory to get the best
• tooth contact.
Replace the O-ring [A] with a new one.
•
Apply grease to the new O-ring.
•
Install:
Differential Unit and Ring Gear
Ring Gear Shim [B]
Ring Gear Cover
•
First tighten the 10 mm (0.39 in.) bolts, then tighten the 8 mm (0.31 in.) bolts.
Torque - Ring Gear Cover Bolts (M10): 47 N·m (4.8 kgf·m,
35 ft·lb)
Ring Gear Cover Bolts (M8): 25 N·m (2.5 kgf·m, 18 ft·lb)
Front Final Gear Case
•
Install the pinion gear unit with the ring gear side of the case facing down.
•
Replace the O-ring [A] with a new one.
•
Apply grease to the new O-ring.
•
Align the air vent passage [B] with the hose nipple [C].
•
Tighten:
Torque - Pinion Gear Bearing Housing Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)
•
Adjust:
Front Final Gear Backlash (see Backlash Adjustment)
Front Final Gear Tooth Contact (see Tooth Contact Adjustment)
Differential Unit and Ring Gear Disassembly
•
Remove the differential unit and ring gear (see Front Final
Gear Case Disassembly).
NOTICE
Do not interchange the right and left side parts in the differential unit.
•
Remove the following parts to disassemble the differential unit.
Differential Case Cap Bolts [A]
Differential Case Cap [B]
○
The clutch plates, springs, spring shims and side gears come out.
Differential Unit and Ring Gear Assembly
•
Inspect the clutch plates (see LSD Clutch Plate Inspection) and the other differential unit parts. Replace any
• damaged parts.
•
Measure and record the thickness of the original clutch spring shim.
•
Apply specified gear oil to the differential unit parts.
Note direction and position of the friction plate and the clutch spring.
Clutch Spring Shim [A]
Clutch Spring [B]
Outside Friction Plate [C]
Steel Plate [D]
Inside Friction Plate [E]
FINAL DRIVE 12-11
•
Be sure to assemble the differential unit and inspect the clutch torque (see LSD Clutch Torque Inspection).
•
Tighten:
Torque - Differential Case Cap Bolts: 32 N·m (3.3 kgf·m, 24 ft·lb)
12-12 FINAL DRIVE
Front Final Gear Case
If the ring gear is removed, install it as follows.
○
Insert the pin [A] to the hole of the ring gear [B] and differential case [C].
○
Apply a non-permanent locking agent to the threads of the ring gear bolts.
•
Tighten:
Torque - Ring Gear Bolts: 82 N·m (8.4 kgf·m, 61 ft·lb)
LSD Clutch Torque Inspection
•
After assembling the differential unit and ring gear, check the LSD clutch torque.
•
Insert both front axles [A] in the differential unit [B].
•
Hold the left front axles (ring gear side) with a vise.
•
Install the hub nut on the other axle.
•
Measure the clutch torque using a torque wrench [C]
○
Turn the wrench at 180 degree/5 seconds of rotation speed.
LSD Clutch Torque
Standard: 7.8
∼ 13 N·m (0.8 ∼ 1.3 kgf·m, 69 ∼ 115
in·lb)
If the clutch torque is out of the specified range, disassemble the differential unit (see Differential Unit and Ring
Gear Disassembly) and replace either of the clutch spring shim.
•
Also, check the clutch plates and replace them as necessary (see LSD Clutch Plate Inspection).
•
To increase clutch torque, increase the thickness of the shim.
○
Change the thickness a little at a time.
•
Recheck the clutch torque and readjust as necessary.
Thickness Part Number
1.2 mm (0.047 in.) 92180-1374
1.3 mm (0.051 in.)
1.4 mm (0.055 in.)
1.5 mm (0.059 in.)
1.6 mm (0.063 in.)
1.7 mm (0.067 in.)
1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
92180-0293
92180-1375
92180-0294
92180-1376
92180-0295
92180-1377
92180-0296
92180-0275
Front Final Gear Case
LSD Clutch Plate Inspection
•
Visually inspect the friction plates and steel plates to see if they show any signs of seizure, overheating, or uneven wear.
If any plates show signs of damage, or if the friction plates have worn past the service limit, replace the friction plates and steel plates as a set.
Outside Friction Plate [A]
Inside Friction Plate [B]
Outside Friction Plate Thickness
Standard: 2.3
∼ 2.4 mm (0.091 ∼ 0.094 in.)
Service Limit: 2.1 mm (0.083 in.)
Inside Friction Plate Thickness
Standard: 2.7
∼ 2.8 mm (0.106 ∼ 0.110 in.)
Service Limit: 2.4 mm (0.094 in.)
Pinion Gear Unit Disassembly
•
Remove the pinion gear unit (see Front Final Gear Case
Disassembly).
•
Pry open the toothed washer tab [A] on the pinion gear slotted nut [B].
•
Unscrew the pinion gear slotted nut.
Special Tools - Pinion Gear Holder [A]: 57001-1281
•
Pull the pinion gear out of the bearing housing.
•
Remove the tapered roller bearing inner race as necessary.
Socket Wrench [B]: 57001-1283
•
Remove the slotted nut, flat washer and toothed washer.
Special Tool - Bearing Puller: 57001-135
Pinion Gear Unit Assembly
•
The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set.
•
Visually inspect the tapered roller bearings for abrasion, color change, or other damage.
If there is any doubt as to the condition of a bearing, replace the bearing housing and the bearings as a set.
•
Be sure to check and adjust the pinion gear bearing preload and the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see
Front Final Bevel Gear Adjustment).
○
When the pinion gear slotted nut is loosened, even if the purpose is not to replace the parts, check and adjust the bearing preload.
FINAL DRIVE 12-13
12-14 FINAL DRIVE
Front Final Gear Case
•
Fit the toothed washer claw [A] into the shaft.
•
Apply molybdenum disulfide oil solution to the threads and seating surface of the pinion gear slotted nut, and tighten it.
Torque - Pinion Gear Slotted Nut: 118 N·m (12.0 kgf·m, 87.0
ft·lb)
If none of the toothed washer tabs [B] align, tighten the nut further just enough to align one of the tabs with a slot
[C] in the nut.
•
Bend the tab over the nut.
Front Final Bevel Gear Adjustment
In order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Also the backlash (distance one gear will move back and forth without moving the other gear) and
tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.
Above three adjustments are of critical importance and must be carried out following the correct sequence and method.
•
When any one of the backlash-related parts are replaced or the pinion gear nut is loosened; even if the purpose is not to replace the parts, check and adjust the bearing preload, the bevel gear backlash, and tooth contact by replacing shims.
•
The amount of backlash is influenced by the ring gear position more than by the pinion gear position.
•
Tooth contact location is influenced by pinion gear position more than by ring gear position.
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 the pinion gear slotted nut [B] is loosened; even if the nut is not removed.
•
Install the pinion gear bearing housing and tighten the pinion gear slotted nut to the specified torque (see Pinion
Gear Unit Assembly).
•
Do not install the oil seal and O-rings, and do not lock the washer until the correct bearing preload is obtained.
NOTICE
To start with, choose a shim or collar so that the bearings are just SNUG with NO play but also with
NO preload.
An over-preload on the bearings could damage the bearings.
•
Apply specified gear oil to the bearings, and turn the gears more than 5 turns to allow the bearings to seat.
•
Measure the bearing preload. Bearing preload is the force or torque which is needed to start the gear shaft turning.
NOTE
○
Preload can be measured either with a spring scale or a beam-type torque wrench. When measured with a spring scale, the preload is designated by force (N, kgf, lb), and when measured with a torque wrench, it is designated by torque (N·m, kgf·m, in·lb).
FINAL DRIVE 12-15
12-16 FINAL DRIVE
Front Final Gear Case
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.
•
Recheck the bearing preload, and readjust as necessary.
•
Measure the bearing preload using a spring scale.
Using Spring Scale
Pinion Gear Bearing Preload:
1.5
∼ 3.0 N (0.15 ∼ 0.31 kgf, 0.34 ∼ 0.67 lb)
○
Hook the spring scale [A] on the handle at a point 200 mm (7.87 in.) [B] apart from the center of the gear shaft.
Hold the bearing housing in a vise so that the gear shaft is vertical.
○
Apply force to the handle horizontally and at a right angle to it.
Special Tool - Pinion Gear Holder [C]: 57001-1281
•
Measure the bearing preload using a torque wrench [A].
Using Torque Wrench
Pinion Gear Bearing Preload Torque:
0.3
∼ 0.6 N·m (0.03 ∼ 0.06 kgf·m, 2.6 ∼ 5.2 in·lb)
Special Tool - Pinion Gear Holder [B]: 57001-1281
•
Backlash Adjustment
•
Check and adjust the gear backlash when any of the backlash-related parts are replaced with new ones.
•
Clean any dirt and oil off the bevel gear teeth.
Assemble the front final gear case (see Front Final Gear
Case Assembly). Do not install the O-rings during adjustment.
○
Check the backlash during tightening of the ring gear cover bolts and stop tightening them immediately if the backlash disappears. Then, change the ring gear shim to a thinner one.
•
Set up a dial gauge against the ditch portion [A] of the pinion gear slotted nut [B] to check gear backlash shown.
•
To measure the backlash, move the pinion gear back and forth while holding the left front axle (ring gear side) steady. The difference between the highest and the lowest gauge reading is the amount of backlash.
•
Measure the backlash at four locations of the nut.
FINAL DRIVE 12-17
12-18 FINAL DRIVE
Front Final Gear Case
If the backlash is not within the limit, replace the ring gear shims. To increase backlash, decrease the thickness of the shim(s). To decrease backlash, increase the thickness of the shim(s).
○
Change the thickness a little at a time.
•
Recheck the backlash, and readjust as necessary.
•
Move the pinion gear [A] back and forth.
Dial Gauge [B]
Bevel Gear Backlash
Standard: 0.14
∼ 0.69 mm (0.0055 ∼ 0.0271 in.) (at
ditch portion of the pinion gear slotted nut)
•
Tooth Contact Adjustment
Clean any dirt and oil off the bevel gear teeth.
•
Apply checking compound to 4 or 5 teeth on the pinion gear.
NOTE
○
Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear.
○
The checking compound must be smooth and firm, with the consistency of tooth paste.
○
Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use one of these for checking the bevel gears.
Front Final Gear Case
•
Assemble the front final gear case (see Front Final Gear
Case Assembly). Do not install the O-rings during adjustment.
•
Turn the pinion gear shaft for one revolution in the drive and reverse (coast) direction, while creating a drag on the ring gear.
○
Use the pinion gear holder [A] and the left front axle.
Special Tool - Pinion Gear Holder: 57001-1281
•
Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth.
○
The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe.
If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown.
•
Then erase the tooth contact patterns and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.
NOTE
○
If the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.
FINAL DRIVE 12-19
12-20 FINAL DRIVE
Front Final Gear Case
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 damaged.
Differential Gear Inspection
•
Visually check the differential gears [A] for scoring, chipping, or other damage.
•
Also, inspect the differential pinion gear shaft [B] and gear housing [C] where the differential gears rub.
If they are scored, discolored, or otherwise damaged, replace them as a set.
Tapered Roller Bearing Inspection
•
Visually inspect the bearings [A] for abrasion, color change, or other damage.
If there is any doubt as to the condition of a bearing, replace it.
Ball Bearing Inspection
•
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.
•
Spin [A] the bearing by hand to check its condition.
If the bearing [B] is noisy, does not spin smoothly, or has any rough spots, replace it.
Oil Seal Inspection
•
Visually inspect the oil seal.
Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
FINAL DRIVE 12-21
12-22 FINAL DRIVE
Bevel Gear Case
Bevel Gear Case Removal
•
Drain the transmission oil (see Transmission Oil Change in the Periodic Maintenance chapter).
•
Remove:
Cargo Bed (see Cargo Bed Removal in the Frame chapter)
Propeller Shaft (see Propeller Shaft Removal)
Right Rear Wheel (see Wheel Removal in the
Wheels/Tires chapter)
Speed Sensor Lead Connector [A]
Bevel Gear Case Bolts [B]
Bevel Gear Case [C]
Bevel Gear Case Installation
•
Check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced
•
(see Bevel Gear Adjustment).
Replace the bevel gear case gasket [A] with a new one.
•
Check to see that the bevel gear case dowel pin [B] is in place.
•
Tighten:
Torque - Bevel Gear Case Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)
Bevel Gear Case Disassembly
•
Remove:
Speed Sensor (see Speed Sensor Removal in the Electrical System chapter)
Holder Nuts [A]
Covers [B]
Holder [C]
If the driven gear assembly is to be disassembled, loosen the housing locknut [A].
Special Tools - Pinion Gear Holder [B]: 57001-1281
Socket Wrench [C]: 57001-1363
Bevel Gear Case
•
Remove:
Driven Gear Assembly [A]
Driven Gear Shim(s) [B]
•
Remove:
Housing Locknut
Bearing Housing [A]
Special Tools - Pinion Gear Holder [B]: 57001-1281
Socket Wrench [C]: 57001-1363
•
Remove the driven gear shaft nut [A].
Special Tool - Pinion Gear Holder [B]: 57001-1281
○
Pressing the spring seat [C], remove the driven gear shaft nut.
•
Remove the bearing holder [A].
Special Tool - Hexagon Wrench, Hex 40 [B]: 57001-1324
•
Remove the ball bearings.
Special Tools - Oil Seal & Bearing Remover: 57001-1058
Bearing Driver Set: 57001-1129
Bevel Gear Case Assembly
•
Install the housing locknut [A] so that the chamfered side
[B] faces to the bearing.
•
Apply a non-permanent locking agent to the threads of the following parts.
Driven Gear Shaft Nut
Bearing Holder
Housing Locknut
•
Tighten:
Torque - Driven Gear Shaft Nut: 108 N·m (11.0 kgf·m, 79.7
ft·lb)
Bearing Holder: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
Housing Locknut: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
FINAL DRIVE 12-23
12-24 FINAL DRIVE
Bevel Gear Case
•
Apply grease to the oil seal lips [A].
•
Tighten:
Torque - Bevel Gear Case Holder Nuts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Drive Bevel Gear Removal
•
Remove the hi/low gear case (see Hi/Low Gear and Shift
Mechanism Removal in the Transmission chapter).
•
Hold the transmission gear holder [A] in a vise.
Special Tool - Transmission Gear Holder: 57001-1676
•
Set the hi/low gear case [A] onto the gear holder.
•
Remove the drive gear nut [B].
•
Remove:
Drive Gear [A]
Drive Gear Shim(s) [B]
Drive Gear Shaft [C]
Drive Bevel Gear Installation
•
Check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced
(see Bevel Gear Adjustment).
•
Apply molybdenum disulfide oil solution to the seating surface of the drive gear nut.
•
Tighten:
Torque - Drive Gear Nut: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
Bevel Gear Case
Bevel Gear Adjustment
In order to prevent one gear from moving away from the other gear under load, the backlash and tooth contact
pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.
When replacing any one of the backlash-related parts, be sure to check and adjust the backlash and tooth contact.
First adjust the backlash, and then tooth contact by replacing shims.
These two adjustments are of critical importance and must be carried out in the correct sequence, using the procedures shown.
FINAL DRIVE 12-25
Backlash Adjustment
•
Check and adjust the gear backlash when any of the backlash-related parts are replaced with new ones.
•
Install the drive gear with the primary shim and assemble the driven gear with the primary shim. Do not install the
• bevel gear case holder during adjustment.
Clean any dirt and oil off the bevel gear teeth.
•
Install the bevel gear case and tighten the case bolts.
○
Check the backlash while tightening the case bolts. Stop tightening them immediately if the backlash disappears and change the shim to a thinner one.
•
Hold the driven gear shaft [A] with a vice.
○
Protect the driven gear shaft with aluminum plates [B].
•
Set up a dial gauge [C] against the middle point [D] of the gear dog side [E].
○
The middle point is position at about 23.5 mm (0.925 in.)
[F] from center.
Gear Dog [G]
•
To measure the backlash, turn the shaft clockwise and counterclockwise. The distance between the highest and lowest gauge reading is the amount of backlash.
If the backlash is not within the limit, replace the shim(s) at the drive and/or driven gear. To increase backlash, decrease the thickness of the shim(s). To decrease backlash, increase the thickness of the shim(s).
Change the thickness a little at a time.
•
Recheck the backlash, and readjust as necessary.
Bevel Gear Backlash
Standard: 0.15
∼ 0.59 mm (0.0059 ∼ 0.0232 in.) (at
middle of gear dog side on drive gear shaft)
12-26 FINAL DRIVE
Bevel Gear Case
Bevel Gear Case (Backlash-Related Parts)
1. Driven Gear Shim(s)
2. Drive Gear Shim(s)
3. Driven Gear Shaft
4. Bearing Housing
5. Bevel Gear Case
6. Ball Bearing
1. Driven Gear Shims
Thickness
0.1 mm (0.004 in.)
0.15 mm (0.006 in.)
0.5 mm (0.020 in.)
0.8 mm (0.031 in.)
1.0 mm (0.039 in.) (primary)
1.2 mm (0.047 in.)
7. Driven Bevel Gear
8. Hi/Low Gear Case
9. Drive Gear Shaft
10. Ball Bearing
11. Gasket
12. Drive Bevel Gear
Part Number
92025-1859
92025-1860
92025-1861
92025-1862
92025-1858
92025-1863
FINAL DRIVE 12-27
Bevel Gear Case
2. Drive Gear Shims
Thickness
0.15 mm (0.006 in.)
0.2 mm (0.008 in.)
0.7 mm (0.028 in.)
0.8 mm (0.031 in.)
0.9 mm (0.035 in.)
1.0 mm (0.039 in.) (primary)
1.1 mm (0.043 in.)
1.2 mm (0.047 in.)
1.3 mm (0.051 in.)
•
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, the exact tooth pattern may not appear.
○
The checking compound must be smooth and firm with the consistency of tooth paste.
○
Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears.
•
Turn the driven bevel gear for 3 or 4 turns in the drive and reverse (coast) directions, while creating a drag on the drive bevel gear.
•
Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and a little closer to the toe of the tooth.
If the tooth contact pattern is incorrect, replace the shim(s) at the drive bevel gear and shim(s) at the driven bevel gear, following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary.
NOTE
○
If the backlash is out of the standard range after changing shims, correct the backlash before checking the tooth contact pattern.
Drive Bevel Gear [A]
Driven Bevel Gear [B]
Bottom [C]
Top [D]
Heel [E]
Toe [F]
Part Number
92025-1573
92025-1574
92025-1534
92180-0288
92180-0289
92180-0290
92025-1575
92180-0291
92025-1533
12-28 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 thickness 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
(0.002 in.) steps if necessary.
Drive Bevel Gear [A]
Driven Bevel Gear [B]
Bottom [C]
Top [D]
Heel [E]
Toe [F]
Example 2: Decrease the thickness of the drive bevel gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the thickness 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
(0.002 in.) steps if necessary.
Drive Bevel Gear [A]
Driven Bevel Gear [B]
Bottom [C]
Top [D]
Heel [E]
Toe [F]
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 damaged.
FINAL DRIVE 12-29
Ball Bearing Inspection
•
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.
•
Spin [A] the bearing by hand to check its condition.
If the bearing [B] is noisy, does not spin smoothly, or has any rough spots, replace it.
Oil Seal Inspection
•
Inspect the oil seals.
Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
Damper Inspection
•
Visually inspect the driven bevel gear [A], cam follower
[B], spring [C] and shaft [D].
Replace any part that appears damaged.
12-30 FINAL DRIVE
Propeller Shafts
Propeller Shaft Removal
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
Tapping Screws [A]
Plate [B]
•
Remove the tapping screws [A].
•
Remove the water pipe bracket bolts [A].
•
Remove the water pipe bracket bolt [A].
•
Remove:
Propeller Shaft Bearing Housing Mounting Bolts [A] and
Nuts
Washers
Collars
Propeller Shafts
•
Move the water pipe [A] and the propeller shaft bearing housing [B] to the outside [C].
•
Remove:
Rear Propeller Shaft [D]
Front Propeller Shaft
Propeller Shaft Installation
•
Wipe the old grease off the splines of the propeller shafts, and grease to them.
•
Inspect the propeller shafts (see Propeller Shaft Inspec-
• tion).
Replace the O-ring [A] with a new one.
•
Apply grease to the new O-ring on the front pinion gear.
•
Install the front propeller shaft yoke [B] on the pinion gear.
•
Put the propeller shaft bearing housing [C] at fully outside position.
•
Install the rear propeller shaft yoke [D] on the rear driven gear shaft so that the thin side [E] of the propeller shaft positions to the rearward.
•
Install the rear propeller shaft yoke [F] on the front propeller shaft rear end [G], aligning the yoke angles [H] of the front and rear propeller shafts.
•
Parallel [I] the propeller shaft bearing housing [J] with the mounting bracket [K].
○
Make the 3 mm (0.12 in.) clearance [L] between the yoke
[B] of the front propeller shaft and the front pinion gear nut
[M].
•
Replace the propeller shaft bearing housing nuts [Q] with new ones.
•
Install:
Propeller Shaft Bearing Housing Bolts [N]
Washers [O]
Collars [P]
Nuts
FINAL DRIVE 12-31
12-32 FINAL DRIVE
Propeller Shafts
Propeller Shaft Bearing Housing Removal
•
Remove:
Front Propeller Shaft (see Propeller Shaft Removal)
Propeller Shaft Bearing Housing Cover Bolts [A] (Both
Sides)
Propeller Shaft Bearing Housing Covers [B] (Both Sides)
•
Wipe off the grease.
•
Remove:
Stop Screws [A]
Front Propeller Shaft [B]
Propeller Shaft Bearing Housing [C]
Propeller Shafts
•
Wipe off the grease.
•
Remove the circlip [A].
Special Tool - Outside Circlip Pliers: 57001-144
•
Remove the propeller shaft bearing housing cover [B].
Propeller Shaft Bearing Housing Installation
•
Clean the front propeller shaft by wiping off the used grease on it.
•
Install:
Propeller Shaft Bearing Housing Cover [A]
New Circlip
Special Tool - Outside Circlip Pliers: 57001-144
•
Insert the front propeller shaft in the propeller shaft bearing housing [B].
•
Tighten:
Torque - Stop Screws: 3.9 N·m (0.40 kgf·m, 35 in·lb)
•
Apply grease about 8 g (0.28 oz) [C] into each cover.
•
Install:
Propeller Shaft Bearing Housing Covers [A]
Propeller Shaft Bearing Housing Cover Bolts [B] (Both
Sides)
•
Tighten:
Torque - Propeller Shaft Bearing Housing Cover Bolts: 3.4
N·m (0.35 kgf·m, 30 in·lb)
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 rattling or sticking.
If it does not, the bearings of the joint are damaged. Replace the propeller shaft with a new one.
FINAL DRIVE 12-33
12-34 FINAL DRIVE
Drive Shaft and Axles
Front Axle Removal
•
Remove:
Steering Knuckle (see Steering Knuckle Removal in the
Steering chapter)
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 (see Drive Shaft and Axle Inspection).
•
Be sure to install the spacer [A] and O-ring [B] in the recess of the front final gear case.
•
Tighten:
Torque - Front Axle Cap Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Rear Drive Shaft and Axle Removal
•
Remove:
Rear Wheels (see Wheel Removal in the Wheels/Tires chapter)
Rear Brake Drums (see Brake Drum Removal in the
Brakes chapter)
Rear Brake Panel Assemblies (with Brake Pipes and
Hoses)
Leaf Springs (see Leaf Spring Removal in the Suspension chapter)
Rubber Bands [A]
Axles [B] and Axle Bracket [C]
•
Slide the dust boots [D] from the drive shafts [E], and pull the one of the axles from the drive shaft, and then the other axle from the shaft.
•
Tap [A] the outside of the rear axle [B], and pull it out from the inside.
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.
FINAL DRIVE 12-35
Rear Drive Shaft and Axle Installation
•
Wipe the old grease off the splines [A] of the drive shafts, axles, and cap oil seals, and grease them.
•
Inspect the drive shafts and axles (see Drive Shaft and
•
Axle Inspection).
•
Align the yoke angles of the drive shaft and axle.
Replace the drive shaft cap gasket with a new one.
If the dust boot was removed, install it on the axle so that the small hole [A] in the boot is toward the axle side.
•
Adjust the transmission oil (see Transmission Oil Change in the Periodic Maintenance chapter).
Drive Shaft and Axle Inspection
•
Visually inspect the splines of the drive shaft and axle.
If they are twisted, badly worn, or chipped, replace the drive shaft and/or axle with a new one.
•
Check that the universal joint and/or ball joint works smoothly without rattling or sticking.
If it does not, the bearings of the joint are damaged. Replace the drive shaft and/or axle with a new one.
12-36 FINAL DRIVE
Drive Shaft and Axles
Dust Boot Inspection
•
Visually inspect the boots [A] in accordance with the Periodic 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 Boot Replacement
Outboard Joint Boot Removal
•
Remove:
Front Axle (see Front Axle Removal)
•
•
Tap the joint portion of the bands [A] with a suitable tool.
•
Scrap the removed boot bands.
Slide the joint boot [B] toward the inboard joint.
•
Tap the bearing housing [A] straight [B] with a plastic hammer to separate it from the shaft.
NOTICE
Do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft.
•
Remove:
Circlip [A]
Boot [B]
Drive Shaft and Axles
•
Outboard Joint Boot Installation
Clean the axle shaft by wiping off the used grease on it.
•
Wind the tape on the splines of the axle shaft in order to protect the joint boot.
•
Install:
New Small Band [A]
New Boot [B]
○
Apply the special grease slightly on the inside of the new boot small diameter, and install the boot on the axle shaft.
NOTICE
Only the special grease that is included with the boot kit can be applied to the boots.
•
Install:
New Circlip [C]
•
Place the special grease tube nozzle in the bore of the housing and squeeze the tube [A] until the grease comes out from the joint bearing.
FINAL DRIVE 12-37
•
Tap the shaft end [A] straight with a plastic hammer until it is locked by the circlip.
•
Squeeze all of the special grease into the bearing housing
[A] and new boot [B].
12-38 FINAL DRIVE
Drive Shaft and Axles
•
Pinch the small boot band [A] with a suitable tool [B] to install it.
•
Compress the axle assembly to the specified length while relieving the air pressure inside the boot.
•
Hold the axle at this setting.
Standard Length of Assembling:
Outboard: 254.5 mm (10.020 in.) [A]
○
Slightly open [A] the larger diameter end of the joint boot to equalize the air pressure inside the boot.
•
Pinch the boot bands [A] with a suitable tool [B] to install it.
○
Compress the suitable tool with a vice, if necessary.
•
Be sure outside diameter of the band [A] is less than the maximum diameter.
Maximum Outside Diameter of Band: 75.9 mm (2.99 in.)
Drive Shaft and Axles
Inboard Joint Boot Removal
•
Remove:
Front Axle (see Front Axle Removal)
Circlip [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
•
Remove:
Collar [C]
Cap [D]
•
Remove:
Front Axle (see Front Axle Removal)
•
•
Tap the joint portion of the bands [A] with a suitable tool.
•
Scrap the removed boot bands.
Slide the joint boot [B] toward the outboard joint.
•
Remove the retaining ring [A].
•
Separate the bearing cup from the axle shaft.
FINAL DRIVE 12-39
•
Remove the steel balls [A].
•
Slide the cage [B] toward the outboard joint.
•
Remove:
Circlip [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
12-40 FINAL DRIVE
Drive Shaft and Axles
•
Remove:
Inner Race [A]
Cage [B]
Inboard Joint Boot [C]
Inboard Joint Boot Installation
•
Install:
New Small Band [A]
New Inboard Joint Boot [B]
Cage [C]
•
Install the inner race [A] so that the flat serration side [B] faces outboard joint.
•
Install:
Circlip [A]
Special Tool - Outside Circlip Pliers: 57001-144
•
Slide the cage [B] on the inner race and install the steel balls [C].
•
Apply the special grease [A] to the steel balls and cage.
Drive Shaft and Axles
•
Squeeze about half a tube (30 grams) of the special grease [A] into the bearing cup [B].
•
Insert the balls and cage assembly in the bearing cup strongly.
FINAL DRIVE 12-41
•
Install the axle shaft [A] into the bearing cap [B].
•
Install the new retaining ring [A] so that the opening [B] is aligned with one of the projections [C].
•
Squeeze the remaining special grease into the bearing cup [A] and new joint boot [B].
•
Pinch the small boot band [A] with a suitable tool [B] to install it.
12-42 FINAL DRIVE
Drive Shaft and Axles
•
Compress the axle assembly to the specified length while relieving the air pressure inside the boot.
•
Hold the axle at this setting.
Standard Length of Assembling:
Outboard 210..3 mm (8.280 in.) [A]
○
Slightly open [A] the larger diameter end of the joint boot to equalize the air pressure inside the boot.
•
Pinch the boot bands [A] with a suitable tool [B] to install them.
○
Compress the suitable tool with a vice, if necessary.
•
Be sure the outside diameter of the band [A] is less than the maximum diameter.
Maximum Outside Diameter of Band: 68.9 mm (2.71 in.)
Ball Bearing Inspection
•
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.
•
Spin [A] the bearing by hand to check its condition.
If the bearing [B] is noisy, does not spin smoothly, or has any rough spots, replace it.
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 otherwise damage.
FINAL DRIVE 12-43
BRAKES 13-1
Brakes
Table of Contents
13
13-2 BRAKES
Exploded View
BRAKES 13-3
Exploded View
No.
1 Bleed Valves
Fastener
2 Brake Hose Banjo Bolts
3 Brake Pipe Nipples
4 Front Axle Nuts
5 Front Brake Panel Mounting Bolts
6 Front Wheel Cylinder Mounting Bolts
7 Master Cylinder Reservoir Cap
8
9
Piston Stop Bolt
Push Rod Locknut
10 Reservoir Clamp Bolt
N·m
5.4
25
18
196
44
10.3
3.4
8.8
17.2
6.1
Torque kgf·m
0.55
2.5
1.8
20.0
4.5
1.1
0.35
0.90
1.8
0.62
ft·lb
48 in·lb
18
13
145
32
91 in·lb
30 in·lb
78 in·lb
13
54 in·lb
Remarks
11. Brake Master Cylinder
12. Brake Pedal
13. Left Front Brake Drum
14. Right Front Brake Drum
15. Bands for Breather Tube of Early Model for KAF950G9
16. Breather Tube (Early Model for KAF950G9: L = 1 480 mm (58.3 in.)
Late Model for KAF950G9 and Later Model: L = 1 100 mm (43.3 in.))
AG: Apply lithium grease (NLGI Grade No.2).
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease.
WL: Apply soap and water solution or rubber lubricant.
B
L
13-4 BRAKES
Exploded View
BRAKES 13-5
Exploded View
No.
Fastener
1 Bleed Valves
2 Brake Pipe Nipples
3 Rear Axle Nuts
4 Rear Brake Panel Mounting Bolts
5 Rear Wheel Cylinder Mounting Nuts
6. Left Parking Brake Lever Linkage
7. Left Rear Brake Drum
8. Parking Brake Lever
9. Right Parking Brake Lever Linkage
10. Right Rear Brake Drum
11. White Mark
12. Yellow Mark
AG: Apply lithium grease (NLGI Grade No.2).
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
N·m
5.4
18
304
44
7.4
Torque kgf·m
0.55
1.8
31.0
4.5
0.75
ft·lb
48 in·lb
13
224
32
65 in·lb
Remarks
B
L
13-6 BRAKES
Specifications
Item
Brake Fluid
Type
Fluid Level
Brake Pedal
Brake Pedal Free Play
Brake Drums
Brake Drum Inside Diameter
Standard
DOT3
Between upper and lower level lines
2
∼ 10 mm (0.08 ∼ 0.39 in.)
180.000
∼ 180.160 mm (7.0866 ∼ 7.0929 in.)
Brake Panel Assemblies
Brake Shoe Lining Thickness 4.5 mm (0.18 in.)
Parking Brake Lever and Cables
Parking Brake Lever Travel 8
∼ 12 notches (clicks) at 200 N (20 kgf, 44 lb)
Service Limit
– – –
– – –
– – –
180.75 mm
(7.116 in.)
1.0 mm
(0.04 in.)
– – –
Special Tools
Clutch Spring Compressor:
57001-1162
Brake Drum Holder:
57001-1325
Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1216
Brake Drum Remover Nuts:
57001-1326
Brake Drum Remover:
57001-1260
Grease Seal Driver Set:
57001-1629
BRAKES 13-7
Brake Drum Pusher, M18 × 1.5:
57001-1261
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
Brake fluid that is contaminated by moisture or dirt, mixed or contains air has a lower boiling point and can cause the brake to be ineffective or fail, and it may cause rubber parts to deterioate, resulting in an accident causing injury or death. 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 mix two types and brands of fluid for use in the brake. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. Don’t add or change the fluid in the rain or when a strong wind is blowing.
If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
Brake Fluid Level Inspection
•
Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.
Brake Fluid Change
•
Refer to the Brake Fluid Change in the Periodic Maintenance chapter.
Brake Line Air Bleeding
•
Tilt up the front cargo hood and remove the maintenance cover [A].
•
Level the reservoir [B] and check that there is plenty of fluid in the reservoir.
NOTE
○
The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.
•
With the reservoir cap off, slowly pump the brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. This bleeds the air from the master cylinder end of the line.
Brake Fluid
•
Remove the wheel for extra clearance (see Wheel Removal in the Wheels/Tires chapter).
•
Connect a clear plastic hose [A] to the bleed valve at the wheel cylinder, and run the other end of the hose into a container.
Brake Panel [B]
NOTE
○
Start with the rear left or right wheel and finish with the front left or right wheel.
•
Bleed the brake line and the caliper as follows.
○
Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the brake pedal [A] until it becomes hard, and apply the brake pedal and hold it.
2. Quickly open and close the bleed valve while holding the brake pedal applied.
3. Release the brake pedal.
•
Tighten:
Torque - Bleed Valves: 5.4 N·m (0.55 kgf·m, 48 in·lb)
•
Repeat the previous step for each wheel.
•
When air bleeding is finished, add fluid up to the upper level in the reservoir.
•
Apply the brake forcefully for a few seconds, and check for fluid leakage around the fittings.
•
Install the removed parts (see appropriate chapters).
Torque - Master Cylinder Reservoir Cap: 3.4 N·m (0.35
kgf·m, 30 in·lb)
BRAKES 13-9
13-10 BRAKES
Brake Pedal and Master Cylinder
Brake Pedal Play Inspection
•
Refer to the Brake Pedal Play Inspection in the Periodic
Maintenance chapter.
Master Cylinder Removal
•
Remove:
Front Cargo Compartment (see Front Cargo Compartment Removal in the Frame chapter)
Brake Hose Banjo Bolts [A]
Brake Pipe Nipple [B] (Unscrew)
•
Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Remove:
Master Cylinder Mounting Bolts [C]
Master Cylinder [D]
Master Cylinder Installation
•
Use a new flat washer on each side of the brake hose fitting.
•
Apply brake fluid to the threads of the brake pipe nipple.
•
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
•
Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
Bleed the brake line after master cylinder installation.
•
Adjust the brake pedal play (see Brake Pedal Play Inspection in the Periodic Maintenance chapter).
•
Check that the brake line has proper fluid pressure and no fluid leakage.
Master Cylinder Disassembly/Assembly
•
Refer to the Brake Master Cylinder Cup and Dust Seal
Replacement in the Periodic Maintenance chapter.
Brake Pedal and Master Cylinder
Master Cylinder Inspection
•
Disassemble the master cylinder (see Brake Master
Cylinder Cup and Dust Seal Replacement in the Periodic
Maintenance chapter).
•
Check that there are no scratches, rust or pitting on the inside of the cylinder [A] and on the outside of the pistons
[B].
If the cylinder or piston shows any damage, replace them.
•
Inspect the primary cups [C] and secondary cups [D].
If a cup is worn, damaged, softened (rotted), or swollen, replace it.
If fluid leakage is noted at the brake push rod, the secondary cup of the rear piston should be replaced.
•
Check the dust cover [E] for damage.
If it is damaged, replace it.
•
Check that the relief [F] and supply [G] ports are not plugged.
If the small relief port becomes plugged, the brake shoes will drag on the drum. Blow the ports clean with compressed air.
•
Check the piston return springs [H] for any damage.
If the spring is damaged, replace it.
BRAKES 13-11
13-12 BRAKES
Brake Hoses and Pipes
Brake Hose and Pipe Inspection
•
Refer to the Brake Hose and Pipe Inspection in the Periodic Maintenance chapter.
Brake Hose and Pipe Replacement
•
Refer to the Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter.
Brake Drums
Brake Drum Removal
•
Remove:
Wheel (see Wheel Removal in the Wheels/Tires chapter)
Cotter Pin [A]
Axle Nut [B]
○
Loosen the axle nut, while applying the brake, and release the brake.
○
You can also loosen the axle nut, using the brake drum holder (special tool).
Special Tool - Brake Drum Holder: 57001-1325
•
Be sure to release the parking brake when removing the rear brake drum.
•
The brake drums are press-fitted on the axles. Use the brake drum remover set and rotor puller (special tools) to remove the drums.
○
Mount the brake drum remover on the drum studs with the remover nuts and washers (parts in the remover set).
Special Tools - Rotor Puller, M16/M18/M20/M22 × 1.5 [A]:
57001-1216
Brake Drum Remover [B]: 57001-1260
Brake Drum Remover Nuts [C]: 57001-1326
Washers [D] (57001-1260)
○
Do not remove the drum bolts. If a drum bolt is damaged, replace the drum.
Brake Drum Installation
•
Apply lithium grease (NLGI Grade No.2) to the brake drum grease seal lips [A] and inside [B] of the drum as shown in the figure.
Grease Seal [C]
Brake Drum [D]
○
Do not allow grease to come in contact with the sliding area of the brake shoes and brake drum.
○
Wipe off any excess grease.
•
Install:
Collar [A] (Rear Brake only)
Brake Drum
BRAKES 13-13
13-14 BRAKES
Brake Drums
•
Mount the brake drum holder [A] securely on the drum studs with the wheel nuts.
Special Tool - Brake Drum Holder: 57001-1325
•
Using the brake drum pusher [B], and tighten it until the pusher stops.
Special Tool - Brake Drum Pusher, M18 × 1.5: 57001-1261
•
And then remove the pusher, install the washer and axle nut.
•
Tighten:
Torque - Front Axle Nuts: 196 N·m (20.0 kgf·m, 145 ft·lb)
Rear Axle Nuts: 304 N·m (31.0 kgf·m, 224 ft·lb)
•
Insert a new cotter pin [A].
NOTE
○
When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [B] up to next alignment.
○
It should be within 30°.
○
Loosen once and tighten again when the slot goes past the nearest hole.
•
Bend the cotter pin [A] over the nut [B].
WARNING
A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin.
Brake Drum Wear
•
Refer to the Brake Wear Inspection in the Periodic Maintenance chapter.
Brake Panel Assemblies
Brake Panel Assy Removal
(Front Brake Panel)
•
Remove:
Front Brake Drum (see Brake Drum Removal)
Brake Hose Retainer
Breather Hose [A]
Brake Pipe Nipple [B]
Front [C]
•
Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Remove the brake panel mounting bolts [A], and then remove the brake panel assy [B].
BRAKES 13-15
(Rear Brake Panel)
•
Remove:
Rear Brake Drum [A] (see Brake Drum Removal)
Brake Hose Retainer
Breather Hose [B]
Cotter Pin and Joint Pin [C]
Brake Pipe Nipple [D] (Unscrew)
•
Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Remove the brake panel mounting bolts [A] and collar [B], and then remove the brake panel assy [C].
13-16 BRAKES
Brake Panel Assemblies
Brake Panel Assy Installation
•
Apply lithium grease (NLGI Grade No.2) to the following portion.
•
Brake Panel Seating Surface (Between Axle and Panel)
Install the brake panel assy.
•
Apply a non-permanent locking agent to the threads of the brake panel mounting bolts.
Torque - Front/Rear Brake Panel Mounting Bolts: 44 N·m
(4.5 kgf·m, 32 ft·lb)
•
Apply brake fluid to the threads of the brake pipe nipple and tighten it.
Torque - Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
•
Install the brake hose retainer.
•
Bleed the brake line after brake drum installation (see
Brake Line Air Bleeding).
•
Be sure to check the brake system for good braking power, no brake drag, and no fluid leakage.
WARNING
After servicing, it takes several applications of the brake pedal before the brake shoes contact the drum, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum.
•
Inspect the parking brake lever inspection (see Parking
Brake Lever Inspection in the Periodic Maintenance chapter).
Brake Panel Disassembly
(Front Brake Panel)
•
Remove:
Front Brake Drum (see Brake Drum Removal)
Brake Pipe Nipple and Vent Hose (see Brake Panel Assy
•
Removal)
Remove the brake shoe springs [A].
•
While pushing the shoe hold-down spring [B], turn the pin
[C] 90° and remove the shoes [D] individually.
NOTE
○
Wrap the brake shoes with a clean cloth to protect the linings from grease or dirt.
•
Remove the brake panel mounting bolts [E], and then remove the brake panel [F].
Front [G]
Brake Panel Assemblies
(Rear Brake Panel)
•
Remove:
Rear Brake Drum (see Brake Drum Removal)
Vent Hose [A]
Grommet [B] of Parking Brake Lever Linkage
Brake Pipe Nipple [C] (Unscrew)
Front [D]
•
Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Remove the brake shoe springs [A].
•
While pushing the shoe hold-down spring [B], turn the pin
[C] 90° and remove the shoes [D] individually.
NOTE
○
Wrap the brake shoes with a clean cloth to protect the linings from grease or dirt.
○
To prevent the rear pin [E] from dropping into the rear axle bracket, tape the pin onto the brake panel.
•
Remove the collar [F] on the rear brake panel.
Front [G]
•
Remove the following for rear brake panel removal.
Cotter Pin [A]
Joint Pin [B]
Parking Brake Lever Linkage [C]
•
Remove:
Brake Panel Mounting Bolts [A]
Rear Brake Panel [B]
BRAKES 13-17
13-18 BRAKES
Brake Panel Assemblies
Brake Panel Assembly
(Front Brake Panel)
•
Apply lithium grease (NLGI Grade No.2) to the following portion.
•
Brake Panel Seating Surface (Between Axle and Panel)
Install the brake panel and wheel cylinder.
•
Apply a non-permanent locking agent to the threads of the brake panel mounting bolts.
•
Tighten:
Torque - Front Brake Panel Mounting Bolts: 44 N·m (4.5
kgf·m, 32 ft·lb)
Front Wheel Cylinder Mounting Bolts: 10.3 N·m
(1.1 kgf·m, 91 in·lb)
•
Apply grease to the following portions.
Contact Points [A] of Brake Panel and Brake Shoes
Wheel Cylinder Piston Ends [B]
Brake Shoe Anchor Ends [C]
•
Apply brake fluid to the threads of the brake pipe nipple and tighten it.
Torque - Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
○
The wheel cylinder has a brake shoe clearance adjuster.
•
Turn [A] either end of the cylinder fully while holding the other end [B]. Both ends are put into the cylinder.
○
Check that there is no grease or any oil on the brake shoe.
If there is grease or any oil on the brake shoe, clean off them with a high flash-point solvent.
•
Install the brake shoe springs on the original positions
(see Brake Shoe Spring Inspection).
(Rear Brake Panel)
•
Apply lithium grease (NLGI Grade No.2) to the following portion.
•
Brake Panel Seating Surface (Between Axle and Panel)
Install the brake panel and wheel cylinder.
•
Apply grease to the shoe clearance adjuster pivots [A].
•
Apply a non-permanent locking agent to the threads of the brake panel mounting bolts.
•
Tighten:
Torque - Rear Brake Panel Mounting Bolts: 44 N·m (4.5
kgf·m, 32 ft·lb)
Rear Wheel Cylinder Mounting Nuts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
•
Apply brake fluid to the thread of the brake pipe nipple and tighten it.
Torque - Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
•
Apply grease to the following portions (refer to front brake above).
Contact Points of Brake Panel and Brake Shoes
Wheel Cylinder Piston Ends
Brake Shoe Anchor Ends
Brake Panel Assemblies
•
Install the parking brake lever linkage [A] and the grommet
[B] with the tabs [C] up.
•
Fit the lips [D] of the grommet as shown in the figure.
Brake Panel [E] (top view of the left rear)
○
Check that there is no grease or any oil on the brake shoe.
If there is grease or any oil on the brake shoe, clean off them with a high flash-point solvent.
•
Install the brake shoe springs on the original positions
(see Brake Shoe Spring Inspection).
○
The parking brake lever linkage has a brake shoe clearance adjuster.
•
Push the ratchet [A] forward and then in to reset the shoe clearance adjuster from the protruding position to its original position. The stop [B] sets the position.
Left Parking Brake Lever Linkage [A] of Rear Brake
Ratchet [B]
Protruding Position [C]
Shoe Clearance Adjuster [E]
Front [F]
Left Parking Brake Lever Linkage [A] of Rear Brake
Ratchet [B]
Original Position [D]
Shoe Clearance Adjuster [E]
Front [F]
•
Pack gaps [A] with grease sparingly.
•
Install the brake shoe springs on the original positions
(see Brake Shoe Spring Inspection).
BRAKES 13-19
13-20 BRAKES
Brake Panel Assemblies
(Front and Rear Brake Panels)
•
Bleed the brake line after drum installation (see Brake
Line Air Bleeding).
•
Be sure to check the brake system for good braking power, no brake drag and no fluid leakage.
WARNING
After servicing, it takes several applications of the brake pedal before the brake shoes contact the drum, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum.
•
Inspect the parking brake lever inspection (see Parking
Brake Lever Inspection in the Periodic Maintenance chapter).
Wheel Cylinder Removal/Installation
•
Refer to the Brake Wheel Cylinder Assembly Replacement in the Periodic Maintenance chapter.
Wheel Cylinder Assembly
•
Before assembly, clean all parts including the wheel cylinder with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder.
NOTICE
Use only brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake.
Brake Panel Assemblies
Wheel Cylinder Inspection
•
Remove the wheel cylinder (see Brake Wheel Cylinder
Assembly Replacement in the Periodic Maintenance
• chapter).
Disassemble the wheel cylinder.
•
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 the cylinder.
•
Inspect the cups.
If a cup is worn, damaged, softened (rotted) or swollen, replace the cylinder.
If fluid leakage is noted at the dust seals, the cylinder should be replaced to renew the cup.
•
Check the dust seals for damage.
If they are damaged, replace the cylinder.
•
Check the spring for any damage.
If the spring is damaged, replace the cylinder.
•
Check the brake shoe clearance adjuster for damage
(front brake only).
If it shows any damage, replace the cylinder.
Dust Seal [A]
Piston [B]
Cup [C]
Shoe Clearance Adjuster (Front) [D]
Spring (Rear) [E]
Brake Shoe Lining Wear
•
Refer to the Brake Wear Inspection in the Periodic Maintenance chapter.
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.
(Front Brake Panel)
•
Install the upper shoe spring in the original position shown, noting the hook direction.
•
Install the lower spring inside the plate of the shoe.
(Rear Brake Panel)
•
Install the upper shoe springs in the original position shown, noting the relative position of the coil to the parking brake lever linkage.
•
Install the lower spring inside the plate of the shoe.
BRAKES 13-21
13-22 BRAKES
Brake Panel Assemblies
Grease Seal Replacement
•
Remove:
Brake Panel Assy (see Brake Panel Assy Removal)
Grease Seal [A]
NOTICE
Be careful not to damage the brake panel when removing the grease seal.
•
Install the grease seal [A] to specified position as shown in the figure.
Top Surface of Grease Seal [B]
Center Bottom of Brake Panel [C]
11.2
∼ 12.0 mm (0.44 ∼ 0.47 in.) [D]
NOTE
○
If the following special tool (Grease Seal Driver Set) is used, the position will be secured.
•
Apply soapsuds to inside area of the new grease seal.
•
Put the brake panel on a suitable flat plate [A] so that the bleed valve fitting [B], boss [C] and parking brake lever linkage [D] (rear only) are not contact to the plate.
•
Put the guide [E] in the panel so that the UP mark [F] faces upward.
Special Tool - Grease Seal Driver Set: 57001-1629
•
Put the grease seal [G] on the brake panel evenly.
•
Put the grease seal driver [A] on the grease seal evenly.
Special Tool - Grease Seal Driver Set: 57001-1629
•
Put the compressor [B] to center on the grease seal driver.
Special Tool - Clutch Spring Compressor: 57001-1162
•
Using a press install the grease seal.
•
Pack lithium grease (NLGI Grade No.2) to the grease seal lips (see Brake Drum Installation).
Parking Brake Lever and Cables
Parking Brake Lever Travel Adjustment
•
Refer to the Parking Brake Lever Inspection in the Periodic Maintenance chapter.
Parking Brake Cable Lubrication/Inspection
•
Refer to the General Lubrication in the Periodic Maintenance chapter.
BRAKES 13-23
SUSPENSION 14-1
Suspension
Table of Contents
14
14-2 SUSPENSION
Exploded View
Exploded View
No.
Fastener
1 Damper Bracket Mounting Nuts
2 Front Suspension Arm Joint Nuts
3 Front Suspension Arm Pivot Bolts
4 Leaf Spring Mounting Bolts (Front)
5 Leaf Spring Mounting Nuts (Rear)
6 Rear Shock Absorber Mounting Nuts
7 Strut Clamp Nuts
8 Strut Locknuts
9 Strut Mounting Locknuts
10 Tie-Rod End Nuts
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
98
59
59
98
N·m
59
78
98
49
44
34
Torque kgf·m
6.0
8.0
10.0
10.0
6.0
6.0
10.0
5.0
4.5
3.5
SUSPENSION 14-3
ft·lb
44
58
72.3
72.3
44
44
72.3
36
32
25
Remarks
R, S
L
R
R
14-4 SUSPENSION
Specifications
Item Standard
Rear Shock Absorbers
Spring Preload Setting Position 1st position
Service Limit
(Usable Range)
1
∼ 5 positions
Special Tool
Steering Stem Nut Wrench:
57001-1100
SUSPENSION 14-5
14-6 SUSPENSION
Struts and Rear Shock Absorbers
Strut (Front Shock Absorber) Removal
•
Remove:
Glove Compartment (see Glove Compartment Removal in the Frame chapter)
Front Wheel (see Wheel Removal in the Wheels/Tires chapter)
Brake Panel (see Brake Panel Assy Removal in the
Brakes chapter)
Brake Hose Retainer [A]
Brake Hose [B] (from Bracket)
Cotter Pin
Strut Clamp Bolt and Nut [C]
•
Remove the strut mounting locknuts [A].
•
Remove the strut [A] from the steering knuckle [B].
Front [C]
Strut (Front Shock Absorber) Installation
•
Insert the strut to the steering knuckle [A] while aligning the notch [B] on the strut with the clamp bolt hole [C] on
• the steering knuckle.
Replace the strut mounting locknuts with new ones.
•
Tighten:
Torque - Strut Mounting Locknuts: 44 N·m (4.5 kgf·m, 32 ft·lb)
Strut Clamp Nuts: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
Struts and Rear Shock Absorbers
•
Insert a new cotter pin [A].
NOTE
○
When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
○
It should be within 30°.
○
Loosen once and tighten again when the slot goes past the nearest hole.
•
Bend the cotter pin [A] over the nut [B].
SUSPENSION 14-7
Strut Spring Replacement
In addition to the standard springs, hard springs are available.
The hard springs stiffen the strut action and accelerate
• the rebound damping.
•
Remove the strut (see Strut (Front Shock Absorber) Removal).
•
Hold the large washer [A] in a vise [B].
Remove:
Locknut [C] and Small Washer
Large Washer
•
Remove:
Holder [A]
Thrust Plate [B]
Dust Seal
Thrust Washer
Upper Spring Seat [C]
Dust Cover [D]
Spring [E]
•
Install the replaced spring.
○
Fit the spring end [A] to the bulge [B] in the lower spring seat [C].
14-8 SUSPENSION
Struts and Rear Shock Absorbers
•
Install:
Dust Cover [A]
Upper Spring Seat [B]
○
Fit the spring end to the bulge [C] in the dust cover and upper spring seat.
•
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]
Locknut [D]
○
Push down the holder, and tighten the locknut.
Torque - Strut Locknuts: 49 N·m (5.0 kgf·m, 36 ft·lb)
Struts and Rear Shock Absorbers
Rear Shock Absorber Preload Adjustment
The spring adjusting sleeve [A] on the rear shock absorbers have 5 positions so that the springs can be adjusted for different terrain and loading conditions. If the spring action feels too soft or too stiff, adjust it in accordance with the following table.
Spring Action
Position
Spring
Force
1 (STD) Weak
2 ↑
Setting
Soft
↑
Load
Light
↑
Terrain Speed
Smooth
↑
Low
↑
3
4 ↓ ↓ ↓ ↓ ↓
5 Strong Hard Heavy Rough High
•
Remove the rear wheel (see Wheel Removal in the
Wheels/Tires chapter).
•
Turn the adjusting sleeve on each rear shock absorber to the desired position with the wrench [A].
Special Tool - Steering Stem Nut Wrench: 57001-1100
○
Both adjusting sleeves (left and right) must be turned to the same relative position.
WARNING
If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. Be sure the adjusters are set equally.
Rear Shock Absorber Removal
•
Remove:
Rear Wheel (see Wheel Removal in the Wheels/Tires chapter)
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 rear wheel temporarily and ground it to load the suspension.
•
Replace the rear shock absorber mounting nuts with new ones.
•
Tighten:
Torque - Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
SUSPENSION 14-9
14-10 SUSPENSION
Struts and Rear Shock Absorbers
Shock Absorber Inspection
•
Visually inspect the shock absorber for breaks or distortion.
If the shock absorber is damaged in any way, replace it.
•
Check for oil leakage at the shock absorber damper unit.
If oil leakage is noted, the shock absorber should be replaced to renew the oil seal.
•
Visually inspect the rubber bushings in the upper and/or lower mountings of the rear shock absorber.
If they are worn, cracked, hardened, or otherwise damaged, replace them with new ones.
Front Suspension Arms
Front Suspension Arm Removal
•
Remove:
Front Wheel (see Wheel Removal in the Wheels/Tires chapter)
Front Guard (see Front Guard Removal in the Frame
• chapter)
•
Hold the front brake drum and panel assembly in position.
Remove the front suspension arm pivot bolts [A].
•
Remove:
Cotter Pin
Front Suspension Arm Joint Nut [A]
Front Suspension Arm Joint (from Steering Knuckle)
○
Remove the front suspension arm joint from the steering knuckle, using a suitable joint remover (see Steering Gear
Assembly Removal in the Steering chapter).
•
Remove the front suspension arm [B].
Front Suspension Arm Installation
•
Clean the tapered portion of the front suspension arm joint and the tapered hole of the suspension arm, or the tapers will not fit snugly.
•
Apply grease to the sealing surface [A] of the front suspension arm joint boot.
•
When the front suspension arm pivot bolts are tightened, install the arm joint to the suspension arm to position the arm within its operating angle.
•
Apply a non-permanent locking agent to the threads of the front suspension arm pivot bolts.
•
Tighten:
Torque - Front Suspension Arm Pivot Bolts: 98 N·m (10.0
kgf·m, 72.3 ft·lb)
Front Suspension Arm Joint Nut: 78 N·m (8.0
kgf·m, 58 ft·lb)
•
Insert a new cotter pin [A].
NOTE
○
When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
○
It should be within 30°.
○
Loosen once and tighten again when the slot goes past the nearest hole.
SUSPENSION 14-11
14-12 SUSPENSION
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, replace it.
•
Check the rubber bushings in the pivots.
Replace any bushings that are worn, cracked, hardened, or otherwise damaged.
Leaf Springs and Dampers
Leaf Spring Removal
•
Remove the rear wheel (see Wheel Removal in the
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.
NOTICE
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Remove:
Rear Shock Absorber [B]
Damper Bracket Mounting Nuts [C] and Leaf Spring
Bracket
Damper and Bracket [D]
•
Remove:
Bolt [A]
Clamp [B]
Leaf Spring Mounting Bolt and Nut [C]
SUSPENSION 14-13
•
Remove:
Leaf Spring Mounting Nuts [A]
Leaf Spring [B]
14-14 SUSPENSION
Leaf Springs and Dampers
Leaf Spring Installation
•
When installing the rubber bushings to the leaf spring, lubricate them with a soap and water solution.
NOTICE
Do not use engine oil or petroleum distillates to lubricate the bushings because they will deteriorate the rubber.
•
Install the rear wheel temporarily and ground it to load the suspension during the mounting nut tightening.
•
Tighten:
Torque - Leaf Spring Mounting Bolts (Front): 98 N·m (10.0
kgf·m, 72.3 ft·lb)
Leaf Spring Mounting Nuts (Rear): 59 N·m (6.0
kgf·m, 44 ft·lb)
Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
•
Apply liquid gasket to the threads of the leaf spring bracket.
Sealant - Three Bond: 1364D
•
Replace the damper bracket mounting nuts with new ones.
•
Tighten the damper bracket mounting nuts in the order as shown in the figure.
Front [A]
Outside [B]
Torque - Damper Bracket Mounting Nuts:
First: 20 N·m (2.0 kgf·m, 15 ft·lb)
Second: 44 N·m (4.5 kgf·m, 32 ft·lb)
•
Final: 59 N·m (6.0 kgf·m, 44 ft·lb)
Apply brake fluid to the brake pipe nipple threads.
•
Tighten:
Torque - Brake Pipe Nipples: 18 N·m (1.8 kgf·m, 13 ft·lb)
•
Bleed the brake line (see Brake Line Air Bleeding in the
Brakes chapter).
Leaf Spring Inspection
•
Visually inspect the leaf spring for breaks or distortion.
If the leaf spring is damaged in any way, replace it.
•
Check the rubber bushings in the mounts and the damper.
Replace any bushings or damper that are worn, cracked, hardened, or otherwise damaged.
STEERING 15-1
Steering
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Assembly ........................................
Adjustment ................................
Inspection..................................
Steering Wheel Centering............
Shaft Removal (KAF950G9
∼
GC/HA)......................................
Shaft Installation (KAF950G9
∼
GC/HA)......................................
Shaft Removal (KAF950GD).....
Shaft Installation (KAF950GD)..
Steering Gear Assembly....................
Removal ....................................
Installation .................................
Adjustment ................................
Tie-Rod Length Adjustment .........
Inspection..................................
Steering Knuckles..............................
Steering Knuckle Removal...........
Steering Knuckle Installation........
Knuckle Bearing Removal............
Knuckle Bearing Installation.........
Knuckle Joint Removal ................
Knuckle Joint Installation .............
System............................................
Precautions ...............................
Outline.......................................
Inquiries to Rider..........................
Self-diagnosis Outline ..................
Self-diagnosis Procedure.............
Service Code Reading .................
Service Code Erasing ..................
Procedures................................
EPS Neutral Position Registration 15-37
(Service Code 11,12) ................
Unregistration (Service
Code 31) ...................................
(Service Code 32) .....................
Inspection (Service Code 33)....
Internal Relay Inspection (Service
Code 34) ...................................
Inspection (Service Code 35)....
Inspection (Service Code 36)....
Inspection (Service Code 37)....
(Service Code 51) .....................
Code 61) ...................................
(LED) Removal..........................
(LED) Inspection .......................
EPS ECU Removal ......................
EPS ECU Installation ...................
Inspection..................................
EPS Motor Removal ....................
EPS Torque Sensor Removal ......
EPS Unit Removal .......................
EPS Unit Installation ....................
Speed Sensor Removal/Installa-
tion ............................................
Speed Sensor Inspection.............
lation..........................................
EPS ECU Relay Inspection..........
Diodes Removal/Installation ........
Diodes Inspection ........................
EPS Fuse 40 A Removal .............
EPS Fuse 7.5 A Removal ............
Fuse Installation...........................
Fuse Inspection............................
15
15-2 STEERING
Exploded View
Exploded View
No.
Fastener
1 EPS Unit Mounting Bolts
2 Rack Guide Spring Cap Locknut
3 Steering Gear Assembly Bracket Bolts
4 Self-lock Nut
5 Strut Clamp Nuts
6 Tie-Rod End Locknuts
7 Tie-Rod End Nuts
8 Universal Joint Clamp Bolts
9. KAF950G9
∼ GC/HA
10. Apply grease on contact plate.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
STEERING 15-3
Torque
N·m kgf·m
20 2.0
39
52
52
98
4.0
5.3
5.3
10.0
44
34
20
4.5
3.5
2.0
ft·lb
15
29
38
38
72.3
32
25
15
Remarks
L
R
15-4 STEERING
Specifications
Item
Steering Wheel
Steering Wheel Free Play
Steering Gear Assembly
Tie-Rod Length
(distance between boot end and locknut)
Standard
0
∼ 20 mm (0 ∼ 0.79 in.)
43.5 mm (1.71 in.)
Service Limit
– – –
– – –
Special Tools
Outside Circlip Pliers:
57001-144
Bearing Driver Set:
57001-1129
Hand Tester:
57001-1394
Knuckle Joint Remover:
57001-1619
STEERING 15-5
Knuckle Joint Driver:
57001-1640
15-6 STEERING
Steering Wheel and Main Shaft Assembly
•
Steering Wheel Position Adjustment
Loosen the steering shaft mounting nuts [A].
•
Adjust the steering wheel position.
•
Tighten the main shaft bracket mounting nuts securely.
Steering Wheel Free Play Inspection
•
Refer to the Steering Inspection in the Periodic Maintenance chapter.
Steering Wheel Centering
•
Test ride the vehicle.
If the steering wheel is not straight when the vehicle is
• traveling in a straight line, do the following.
Check the tie-rod length and adjust it if necessary.
•
Remove the wheel cap and horn switch (KAF950G9
∼ GC/HA, see Steering Wheel and Steering Shaft Removal).
•
Remove the wheel cover (KAF950GD, see Steering
Wheel and Steering Shaft Removal).
•
•
Loosen the self-lock nut [A].
•
Push the vehicle in a straight line with no one aboard, and stop it without turning the steering wheel.
•
Remount the steering wheel so that it is straight ahead.
Install:
Spring Washer [B] (KAF950G9
∼ GC/HA)
Washer [C] (KAF950GD)
[D] KAF950G9
∼ GC/HA
[E] KAF950GD
•
Tighten:
Torque - Self-lock Nut: 52 N·m (5.3 kgf·m, 38 ft·lb)
•
Install:
Horn Switch and Wheel Cap (KAF950G9
∼ GC/HA, see
Steering Wheel and Steering Shaft Installation)
Wheel Cover (KAF950GD, see Steering Wheel and
Steering Shaft Installation)
•
Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
Steering Wheel and Main Shaft Assembly
Steering Wheel and Steering Shaft Removal
(KAF950G9
∼
GC/HA)
•
Remove the wheel cap together with the horn switch as follows.
○
Insert a thin driver [A] into the hole [B], and unlock the stopper.
○
Pry the one side part of the switch with a thin driver for the stopper [A] is free.
○
Remove the wheel cap [B] together with the horn switch.
•
When removing the horn switch, unlock the stoppers [A].
STEERING 15-7
•
Remove:
Self-lock Nut [A] and Spring Washer
Steering Wheel [B]
•
Cut the bands [A].
•
Disconnect the horn switch and connector [B].
15-8 STEERING
Steering Wheel and Main Shaft Assembly
•
Remove:
Screws [A] and Holder
Horn Switch Contact [B]
•
Remove:
Front Cargo Compartment (see Front Cargo Compartment Removal in the Frame chapter)
Universal Joint Clamp Bolt [A]
•
Remove:
Steering Shaft Mounting Bolts, Washers and Nuts [A]
Steering Shaft [B]
Steering Wheel and Steering Shaft Installation
(KAF950G9
∼
GC/HA)
•
Apply grease to the dust cover lips [A].
•
Install the steering shaft [A] to the upper universal joint
[B].
•
Install the universal joint clamp bolt [C] while aligning the notch on the steering shaft with the clamp bolt hole on the upper universal joint, and tighten it temporary.
•
Replace the steering shaft mounting nuts [F] with new ones.
•
Install the steering shaft mounting bolts [D], washers [E] and nuts.
•
Tighten the universal joint clamp bolt to the specified torque.
Torque - Universal Joint Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Steering Wheel and Main Shaft Assembly
•
Install:
Horn Switch Contact [A]
Holder [B]
Screws [C]
○
Position the horn switch contact on the projection [D].
•
Connect the horn switch lead connector [A] and clamp the bands [B].
STEERING 15-9
•
Mount the steering wheel on the steering shaft temporarily.
•
Adjust the following items.
Steering Wheel Position (see Steering Wheel Position
Adjustment)
Steering Wheel Centering (see Steering Wheel Center-
• ing)
Replace the self-locknut with a new one.
•
Tighten:
Torque - Self-lock Nut: 52 N·m (5.3 kgf·m, 38 ft·lb)
•
Install the horn switch [A] as follows.
○
Fit the front stoppers [B] in the recesses [C] of the steering wheel.
○
Fit the rear stopper [A] in the recess of the steering wheel and push the rear part until sound click.
15-10 STEERING
Steering Wheel and Main Shaft Assembly
•
Install the wheel cap [A] so that the arrow mark [B] faces front and the stoppers [C] fit the recesses [D] of the horn switch.
•
Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
Steering Wheel and Steering Shaft Removal
(KAF950GD)
•
Clear the hook portions [A] from the steering wheel to remove the wheel cover [B].
•
Remove the wheel cover.
•
Remove:
Steering Wheel Mounting Nut [A] and Washer [B]
Steering Wheel
•
Remove the washer [A].
•
Remove:
Front Cargo Compartment (see Front Cargo Compartment Removal in the Frame chapter)
Universal Joint Clamp Bolt [A]
Steering Wheel and Main Shaft Assembly
•
Remove:
Steering Shaft Mounting Bolts, Washers and Nuts [A]
Steering Shaft [B]
•
Remove:
Clamp Bolt [A]
Intermediate Shaft [B]
Steering Wheel and Steering Shaft Installation
(KAF950GD)
•
Apply grease to the dust cover lips [A].
•
Install the steering shaft [A] to the upper universal joint
[B].
•
Install the universal joint clamp bolt [C] while aligning the notch on the steering shaft with the clamp bolt hole on the upper universal joint, and tighten it temporary.
•
Replace the steering shaft mounting nuts [F] with new ones.
•
Install the steering shaft mounting bolts [D], washers [E] and nuts.
•
Tighten:
Torque - Universal Joint Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
STEERING 15-11
15-12 STEERING
Steering Wheel and Main Shaft Assembly
•
Install the washer [A].
•
Mount the steering wheel on the steering shaft temporarily.
•
Adjust the following items.
Steering Wheel Position (see Steering Wheel Position
Adjustment)
Steering Wheel Centering (see Steering Wheel Center-
• ing)
Replace the steering wheel mounting nut with a new one.
•
Tighten:
Torque - Steering Wheel Mounting Nut: 52 N·m (5.3 kgf·m,
38 ft·lb)
•
Insert the hook portions [A] into the holes [B] of the steering wheel.
Steering Gear Assembly
Steering Gear Assembly Removal
•
Remove:
Front Wheels (see Wheel Removal in the Wheels/Tires chapter)
Radiator (see Radiator Removal in the Cooling System chapter)
Cotter Pins (Both Sides)
Tie-Rod End Nuts [A] (Both Sides)
Tie-Rod Ends [B] from Steering Knuckles (Both Sides)
NOTICE
Do not loosen the tie-rod end locknuts [C], or the toe-in of the front wheels will be changed.
○
Remove the tie-rod end [A] from the steering knuckle, using a suitable joint remover [B].
STEERING 15-13
•
Remove:
Left Radiator Side Cover (see Radiator Side Cover Removal in the Frame chapter)
Water Hoses [A]
Horn Ground Lead Terminal [B]
•
Remove the steering gear assembly bracket bolts [C] and brackets [D] .
•
Remove the rubber dumpers [A].
15-14 STEERING
Steering Gear Assembly
•
Remove the mounting bolts [A] of the water pipe.
•
Remove the universal joint clamp bolt [A].
If the clamp bolt becomes hard to turn, search the position that it can be easily turned while turning the steering wheel slowly.
•
Pull out the rubber boot [B] upward temporary.
•
Move the steering gear assembly, and pull off the shaft
[A] from the lower universal joint [B].
○
Lower the steering gear assembly, and then pull it forward.
•
Remove the rubber boot [C].
•
Remove the steering gear assembly [A] from the vehicle left side [B].
Steering Gear Assembly Installation
•
Adjust the following items if necessary.
Steering Gear Preload (see Steering Gear Preload Adjustment)
Tie-Rod Length (see Tie-Rod Length Adjustment)
•
Clean the tapered portion of the tie-rod end joint and the tapered hole of the steering knuckle, or the tapers will not fit snugly.
•
Apply grease to the sealing surface [A] of the tie-rod end joint boot.
Steering Gear Assembly
•
Install the rubber boot [A] on the shaft [B] of the steering gear assembly temporary.
•
Install the shaft of the steering gear assembly to the lower universal joint [C].
•
Install the universal joint clamp bolt [D] while aligning the notch on the shaft of the steering gear assembly with the clamp bolt hole on the lower universal joint, and tighten it temporary.
•
Install:
Rubber Dampers [E]
Brackets [F]
•
Apply a non-permanent locking agent to the steering gear assembly bracket bolts [G] and tighten them evenly.
Torque - Steering Gear Assembly Bracket Bolts: 52 N·m
(5.3 kgf·m, 38 ft·lb)
•
Tighten the universal joint clamp bolt to the specified torque.
Torque - Universal Joint Clamp Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)
[H] KAF950G9
∼ GC/HA
[I] KAF950GD
•
Install the rubber boot [A] so that the mark (F, Arrow) [B] faces forward.
STEERING 15-15
•
Tighten:
Torque - Tie-Rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
•
Insert a new cotter pin [A].
NOTE
○
When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
○
It should be within 30°.
○
Loosen once and tighten again when the slot goes past the nearest hole.
15-16 STEERING
Steering Gear Assembly
•
Bend the cotter pin [A] over the nut [B].
•
Check the toe-in of the front wheels (see Toe-in Adjustment in the Wheels/Tires chapter).
•
Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
•
Steering Gear Preload Adjustment
Loosen the locknut [A].
•
Tighten the rack guide spring cap [B] to 12.3 N·m (1.25
kgf·m, 109 in·lb) of torque.
•
Back off the cap 40
∼ 50°.
•
Tighten the locknut while preventing the cap from turning.
Torque - Rack Guide Spring Cap Locknut: 39 N·m (4.0
kgf·m, 29 ft·lb)
Pinion [C]
Rack [D]
Rack Guide [E]
Spring [F]
•
Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
Tie-Rod Length Adjustment
•
Refer to the Toe-in Adjustment in the Wheels/Tires chapter.
Tie-Rod Length [A]
Front [B]
Steering Joint Dust Boot Inspection
•
Refer to the Steering Joint Dust Boot Inspection in the
Periodic Maintenance chapter.
Steering Knuckles
Steering Knuckle Removal
•
Remove:
Front Brake Panel Assembly (see Brake Panel Assy Removal in the Brakes chapter)
Cotter Pin
Tie-Rod End Nut [A]
Tie-Rod End [B] from Steering Knuckle
○
Remove the tie-rod end from the steering knuckle, using a suitable joint remover (see Steering Gear Assembly Removal).
NOTICE
Do not loosen the tie-rod end locknuts [C], or the toe-in of the front wheels will be changed.
•
Remove:
Brake Hose Retainer [D]
Cotter Pin
Strut Clamp Bolt and Nut [E]
•
Remove:
Cotter Pin
Front Suspension Arm Joint Nut [A]
Front Suspension Arm Joint from Steering Knuckle
○
Remove the front suspension arm joint from the steering knuckle, using a suitable joint remover (see Steering Gear
Assembly Removal).
•
Remove the steering knuckle [B].
Steering Knuckle Installation
•
Using a cleaning fluid, clean off any oil or dirt on the tapered portions of the front suspension arm joint and the tie-rod end joint, and the tapered holes of the steering knuckle and the front suspension arm. Then dry them with a clean cloth.
•
Apply grease to the following portions.
Axle Bearing Grease Seal Lips
Front Suspension Arm Joint Boot Sealing Surfaces [A]
•
Tighten:
Torque - Strut Clamp Nuts: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
Front Suspension Arm Joint Nuts: 78 N·m (8.0
kgf·m, 58 ft·lb)
Tie-Rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
STEERING 15-17
15-18 STEERING
Steering Knuckles
•
Insert a new cotter pin [A].
NOTE
○
When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment.
○
It should be within 30°.
○
Loosen once and tighten again when the slot goes past the nearest hole.
•
Bend the cotter pin [A] over the nut [B].
•
Check the toe-in of the front wheels (see Toe-in Adjustment in the Wheels/Tires chapter).
•
Be sure to register the neutral position of the EPS (see
EPS Neutral Position Registration).
Knuckle Bearing Removal
•
Remove:
Steering Knuckle (see Steering Knuckle Removal)
Grease Seal [A]
•
Drive the bearing [A] out using a suitable bearing driver from the bearing driver set.
Special Tool - Bearing Driver Set: 57001-1129
Knuckle Bearing Installation
•
Press in the bearing until it is bottomed.
Special Tool - Bearing Driver Set [A]: 57001-1129
•
Replace the grease seal with a new one.
Steering Knuckles
Knuckle Joint Removal
•
Remove:
Steering Knuckle (see Steering Knuckle Removal)
Circlip [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
•
Remove the knuckle joint [A] using a press.
Special Tool - Knuckle Joint Remover [B]: 57001-1619
○
First, press the knuckle joint until the remover end [C] touches the knuckle.
○
Second, move the remover [A] so that its center align with the center of the knuckle joint.
○
Press the knuckle joint, and remove it.
Knuckle Joint Installation
•
Press the knuckle joint [A] until it is bottomed.
Special Tool - Knuckle Joint Driver [B]: 57001-1640
•
Replace the circlip with a new one.
Special Tool - Outside Circlip Pliers: 57001-144
STEERING 15-19
15-20 STEERING
EPS (Electric Power Steering) System
Parts Location
EPS Warning Indicator Light (LED) [A]
EPS Motor [A]
[B] KAF950G9
∼ GC/HA
[C] KAF950GD
EPS Torque Sensor [A]
EPS Unit [B] (with EPS Motor and EPS Torque Sensor)
EPS ECU [A]
EPS (Electric Power Steering) System
Speed Sensor [A]
EPS Self-diagnosis System Connector [A]
EPS Fuse Box 1 (EPS Fuse 40 A ) [B]
EPS Fuse Box 2 (EPS Fuse 7.5 A ) [C]
STEERING 15-21
15-22 STEERING
EPS (Electric Power Steering) System
EPS System Wiring Diagram (KAF950G9, GA/HA)
1. EPS ECU
2. EPS Fuse 40 A
3. EPS Motor
4. EPS Torque Sensor
5. EPS Self-diagnosis System Connector
6. Speed Sensor
7. EPS Warning Indicator Light (LED)
○
Color Codes:
BK: Black
BL: Blue
BR: Brown
G: Green
P: Pink
R: Red
W: White
Y: Yellow
8. EPS Fuse 7.5 A
9. Oil Pressure Warning Indicator Light
10. Main Switch
11. Battery 12 V 52 Ah
12. Main Fuse 30 A
13. Fuse Box 2
14. Oil Pressure Switch
EPS (Electric Power Steering) System
EPS System Wiring Diagram (KAF950GB
∼)
STEERING 15-23
1. EPS ECU
2. EPS Fuse 40 A
3. EPS Motor
4. EPS Torque Sensor
5. EPS Self-diagnosis System Connector
6. Speed Sensor
7. EPS Warning Indicator Light (LED)
8. EPS Fuse 7.5 A
○
Color Codes:
BK: Black
BL: Blue
BR: Brown
G: Green
P: Pink
R: Red
W: White
Y: Yellow
9. EPS ECU Relay
10. Diodes
11. Oil Pressure Warning Indicator Light
12. Main Switch
13. Battery 12 V 52 Ah
14. Main Fuse 30 A
15. Fuse Box 2
16. Oil Pressure Switch
15-24 STEERING
EPS (Electric Power Steering) System
Terminal Names
1. Unused
2. Unused
3. Unused
4. Ground for EPS ECU: BK/Y
5. Power Supply (from Battery): W
6. EPS Motor 1 : BK
7. EPS Motor 2 : R
8. External Communication Line: G
9. EPS Warning Indicator Light (LED): BK/W
10. Unused
11. Unused
12. Speed Sensor Signal: P
13. Unused
14. Unused
15. EPS Torque Sensor Signal 1: Y/BK
16. Power Supply (from Main Switch): BL/R
17. Unused
18. Unused
19. Unused
20. EPS Self-diagnosis System Terminal: BL
21. Unused
22. Ground for EPS Torque Sensor: BK/BL
23. EPS Torque Sensor Signal 2: Y/R
EPS (Electric Power Steering) System
EPS System Servicing Precautions
There are number of important precautions that should be followed servicing the EPS system.
○
The EPS system operates while running the engine.
○
This EPS system is designed to be used with a 12 V battery as its power source. Do not use any other battery except for a 12 V battery as a power source.
○
Do not reverse the battery cable connections. This will damage the EPS ECU.
○
To prevent damage to the EPS system parts, do not disconnect the battery cables or any other electrical connections when the main switch ON or while the engine is running.
○
Do not short the cables that are directly connected to the battery positive (+) terminal to the chassis ground.
○
Do not turn the main switch ON while any of the EPS electrical connectors are disconnected. The EPS ECU memorizes service codes.
○
Do not spray water on the electrical system parts, EPS system parts, connectors, leads and wiring.
○
If a transceiver is installed on the vehicle, make sure that operation of the EPS system is not influenced by electric wave radiated from the antenna. Locate the antenna as far as possible away from the EPS ECU.
○
Whenever the electrical connections of the EPS system are to be disconnected, first turn the main switch OFF.
Conversely, make sure that all the electrical connections of the EPS system are firmly reconnected before turning on the main switch.
○
When reconnecting the connector, connect these connectors securely until they click [A].
○
The EPS system parts should never be struck sharply, as with a hummer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
○
The EPS system parts can not be disassembled. Even if a fault is found, do not try to disassemble and repair the
EPS system parts, replace it.
○
With the front wheel lifted from the ground, do not move the front wheel quickly. An abnormal voltage is generated and the EPS ECU may be damaged.
○
Using a fully charged battery. If the power supply voltage of the EPS ECU becomes 10 V or less, EPS system does not operate correctly.
STEERING 15-25
15-26 STEERING
EPS (Electric Power Steering) System
○
There are 40 A and 7.5 A fuses for the EPS system. If the fuse is blown, the EPS system does not operate. In this case, the EPS warning indicator light (LED) does not light up and even if engine is started. Replace the fuse.
WARNING
When replacing the 40 A fuse, first disconnect the battery cables to avoid electrical shock.
○
If the EPS system fuses are blown frequently, inspect the
EPS system parts.
○
If the EPS ECU was replaced, be sure to register the EPS neutral position (see EPS Neutral Position Registration).
The EPS system can not function until the neutral position is registered in the new EPS ECU. In this case, the EPS warning indicator light (LED) blinks immediately after engine starts.
○
If the following parts were removed or replaced, be sure to register the neutral position of the EPS (see EPS Neutral Position Registration). If the neutral position does not register, EPS system does not operate correctly.
EPS Unit
Upper and Lower Universal Joints
Steering Gear Assembly
Steering Knuckles
○
Do not loosen the following bolts and nuts except repair work. If the following bolts and nuts were loosened, be sure to register the EPS neutral position (see EPS Neutral Position Registration). If the neutral position does not register, EPS system does not operate correctly.
Steering Gear Assembly Bracket Bolts
Tie-Rod End Nuts
Universal Joint Clamp Bolts
EPS Unit Mounting Bolts
○
Before delivering the vehicle to the customer, be sure to erase any service codes which might be stored in the EPS
ECU. Using the self-diagnosis function, confirm that the
EPS warning indicator light (LED) lights up (This shows that there is no service code in the EPS ECU.).
EPS System Troubleshooting Outline
The EPS ECU is equipped with a self-diagnosis function.
When an abnormality in the EPS system occurs, the EPS
ECU lights the EPS warning indicator light (LED) [A] to alert the rider. In addition, the condition of the problem is stored in the memory of the EPS ECU as service codes and in the self-diagnosis mode, the service code is indicated by the number of times the EPS warning indicator light (LED) blinks.
EPS (Electric Power Steering) System
If due to a malfunction, the EPS warning indicator light
(LED) remains lit, try to understand the background of the trouble before starting the repair work. First ask the rider about the conditions [A] of the trouble, and then start to examine the cause [B] of the trouble. Do not rely solely on the self-diagnosis function, use common sense; for example, check the connections of the connector.
If the problem is with the following parts, the EPS ECU can not recognize these problem. Therefore, EPS warning indicator light (LED) does not light up, and service code is not indicated.
EPS Warning Indicator Light (LED)
EPS ECU Power Source Wiring and Ground Wiring
Speed Sensor
When the repair has been done, the EPS warning indicator light (LED) lights up immediately after engine starts, and goes off after 1 second. This shows that EPS system is normal. But, service codes detected once by the EPS ECU will be memorized in the EPS ECU. Therefore, after maintenance work ends, be sure to erase the service codes with service code erase mode. Do not erase the service codes during troubleshooting. Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work. Before erasing the service codes, record them as problem history. The problem history can be referred when solving unstable trouble.
Even when the EPS system is operating normally, the
EPS warning indicator light (LED) may light up under strong electrical interference. If the indicator light lights up, turn the main switch OFF and then erase the service code.
Much of the EPS system troubleshooting work consists of confirming continuity of the wiring. The EPS system parts are assembled and adjusted by the manufacturer, so there is no need to disassemble or repair them. Replace them as an assembly.
The basic troubleshooting procedures and precautions are listed below.
•
Using a fully charged battery. A fully charged battery is a must for conducting reliable self-diagnosis function.
•
Measure coil winding resistance when the EPS system part is cold (at room temperature).
•
Check wiring and connections from the EPS ECU connector to the suspected faulty EPS system part, using the hand tester.
Special Tool - Hand Tester: 57001-1394
STEERING 15-27
15-28 STEERING
EPS (Electric Power Steering) System
•
Visually inspect the wiring for signs of burning or fraying.
If any wiring is poor, replace the damaged wiring.
•
Pull each connector [A] apart and inspect it for corrosion, dirt and damage.
If the connector is corroded or dirty, clean it carefully. If it
• is damaged, replace it.
Check the wiring for continuity.
○
Use the wiring diagram to find the ends of the lead which is suspected of being problem.
○
Connect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001-1394
○
Set the hand tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the main harness [B] if necessary.
•
Narrow down suspicious parts and close in on the faulty
EPS system part by repeating the continuity tests.
If no abnormality is found in the wiring or connectors, the
EPS system parts are the next likely suspects. Check each part one by one.
If an abnormality is found, replace the affected EPS system part.
If all the parts and wirings are good, be sure to inspect the power supply voltage of the EPS ECU.
If the power supply voltage is good, replace the EPS ECU.
EPS (Electric Power Steering) System
EPS System Diagnosis Flow Chart
STEERING 15-29
15-30 STEERING
EPS (Electric Power Steering) System
Inquiries to Rider
○
Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with.
○
Try to find out exactly what problem occurs under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem in the shop.
○
The following sample diagnosis sheet will help prevent you from overlooking any keys, so always use it.
Sample Diagnosis Sheet
Rider name:
Year of initial registration:
Registration No. (license plate No.):
Model:
Engine No.:
Date problem occurred:
Weather:
Phenomenon
Frame No.:
Problem frequency:
Mileage:
□
Steering wheel is heavy.
□
Steering wheel is too light.
□
Steering wheel is unbalance.
□
Steering wheel is naturally turned to one side.
□
When operating the steering wheel, make vibration or noise.
□
When operating the steering wheel, the headlight darkens.
□
EPS system does not operate.
□
Other
Engine conditions at problem
□
At start-up
□
After starting
Driving conditions
EPS warning indicator light (LED) conditions
□
At high-speed
□
At low-speed
□ lights up immediately after engine starts, and goes off after 1 second.
□ lights up immediately after engine starts, and stays on.
□
Blinks immediately after engine starts, and stays on.
□
Does not light up.
□
Sometimes lights up.
Self-diagnosis Outline
The EPS self-diagnosis system has two modes and can be switched to another mode by connecting terminals of the
EPS self-diagnosis system connector [A].
User Mode
The EPS ECU notifies the rider of troubles in EPS system by lighting the EPS warning indicator light (LED) when EPS system parts are faulty, and initiates fail-safe function. In this case, EPS ECU stops the EPS motor operation.
Dealer Mode
The EPS warning indicator light (LED) emits service code
(s) to show the problem (s) by blinking.
EPS (Electric Power Steering) System
Self-diagnosis Procedure
○
When problem occurs with the EPS system, the EPS warning indicator light (LED) [A] lights up.
NOTE
○
Use a fully charged battery when conducting self-diagnosis.
Otherwise, the EPS warning indicator light (LED) blinks very slowly or does not blink.
○
Keep the EPS self-diagnosis system connector terminals connected during self-diagnosis, with an auxiliary lead.
•
•
Turn the main switch OFF.
•
Tilt up the front seat.
Disconnect the EPS self-diagnosis system connector [A].
•
Connect an auxiliary lead [A] to the terminals of the EPS self-diagnosis system connector [B] as shown.
Auxiliary Lead Connections:
BL Lead [C] ←→ BK/Y Lead [D]
○
The BK/Y lead terminal is connected to the battery (–) terminal.
•
Start the engine.
•
Count the blinks of the indicator light to read the service code (see Service Code Reading).
NOTE
○
Keep connections of the auxiliary lead until you finish reading the service code.
○
If there is no service code, the EPS warning indicator light (LED) remains lit and service code is not indicated.
•
Any of the following procedures ends the self-diagnosis mode.
○
When the main switch is turned OFF.
○
When the auxiliary lead is disconnected from the terminals of the EPS self-diagnosis system connector.
STEERING 15-31
15-32 STEERING
EPS (Electric Power Steering) System
Service Code Reading
○
Service codes are shown by a series of long and short blinks of the EPS warning indicator light
(LED) as shown below.
○
Read 10th digit and unit digit as the EPS warning indicator light (LED) blinks.
○
The EPS ECU can memorize all the service codes except the service code 31.
○
When there are plural service codes in the memory of the EPS ECU, the service codes are displayed from the lowest number code in the ascending order. The display is repeated until the main switch is turned OFF or the auxiliary lead is disconnected from the terminals of the EPS self-diagnosis system connector.
○
For example, if two problems occurred in the order of 32,12, the service codes are displayed from the lowest number code in the order listed.
(12→32) → (12→32) →· · · (repeated)
Service Code Erasing
○
The service code memorized in the EPS ECU can not be erased even if the main switch is turned OFF or battery cables are disconnected.
○
Refer to the Service Code Erasing Procedure for the service code erasure.
STEERING 15-33
EPS (Electric Power Steering) System
Service Code Table
Service
Code
EPS Warning Indicator Light (LED) Failure Parts
11
12
31 (1)
–
–
–
Problems
Power supply voltage from main switch is abnormal.
Power supply voltage from battery is abnormal.
EPS neutral position is unregistration.
32
33
34
35
36
37
51
61
Current sensor is trouble.
FET(Field Effect Transistor) for
EPS motor is trouble.
Internal relay is trouble.
EPS ECU
CPU (Central Processing Unit) is trouble.
Direction distinction circuit for
EPS torque sensor is trouble.
Boosting transformer circuit is trouble.
EPS torque sensor is trouble.
EPS Unit
EPS motor is trouble.
NOTE:
(1):This code appears in the following condition.
○
When the EPS ECU was replaced and the EPS neutral position is not registered in the new EPS ECU.
In this case, the EPS warning indicator light (LED) blinks immediately after engine starts. But, the service code 31 is not memorized in the EPS ECU. Therefore, the service code 31 will disappear when the EPS neutral position was registered in the new EPS ECU.
15-34 STEERING
EPS (Electric Power Steering) System
Self-diagnosis Flow Chart
EPS (Electric Power Steering) System
Service Code Erasing Procedures
NOTE
○
Keep the self-diagnosis system connector terminals connected during service code erase mode with an auxiliary lead.
○
The EPS motor does not operate during service code erase mode.
•
Start the service code erase mode with the following procedure.
○
First, turn the main switch OFF.
○
Second, connect an auxiliary lead to the terminals of the
EPS self-diagnosis system connector by the same procedure as self-diagnosis mode (see Self-diagnosis Procedure).
○
Third, lift the front wheel off the ground.
○
Fourth, turn the steering wheel fully to the left and keep it.
○
Fifth, start the engine while turning the steering wheel fully to the left.
○
The EPS warning indicator light (LED) ights up for 4 seconds and goes off.
If the service code is indicated, turn the main switch OFF and repeat from fourth procedure again.
○
Sixth, free the hands from the steering wheel after indicator light goes off.
○
After 4 seconds, the EPS warning indicator light (LED) lights up.
○
Seventh, turn the steering wheel fully to the left and keep it, after indicator light lights up.
○
After 4 seconds, the EPS warning indicator light (LED) goes off.
○
Eighth, free the hands from the steering wheel after indicator light goes off.
○
After 4 seconds, the EPS warning indicator light (LED) blinks two times. This blink shows that the service code was erased.
If the EPS warning indicator light (LED) does not blink or lights up, turn the main switch OFF and repeat from fourth procedure again.
○
Lastly, turn the main switch OFF within 5 seconds after indicator light blinks two times, end the service code erase mode.
If the main switch is not turned OFF within 5 seconds, the
EPS ECU starts the EPS neutral position registration.
NOTE
○
The EPS neutral position registration is same procedure as until eighth procedure.
○
After finishing the service code erase mode, enter the self-diagnosis mode again to confirm that the service codes have been erased.
If all codes have been erased, the EPS warning indicator light (LED) remains lit and service code is not indicated.
STEERING 15-35
15-36 STEERING
EPS (Electric Power Steering) System
Service Code Erasing Flow Chart
EPS (Electric Power Steering) System
EPS Neutral Position Registration
NOTE
○
Keep the self-diagnosis system connector terminals connected during the EPS neutral position registration with an auxiliary lead.
○
Be sure to lift the front wheel off the ground. The EPS neutral position can not be registered correctly with the front wheel on the ground.
○
The EPS motor does not operate during EPS neutral position registration.
•
Register the EPS neutral position with the following procedure.
○
First, turn the main switch OFF.
○
Second, connect an auxiliary lead to the terminals of the
EPS self-diagnosis system connector by the same procedure as self-diagnosis mode (see Self-diagnosis Procedure).
○
Third, lift the front wheel off the ground.
○
Fourth, turn the steering wheel fully to the left and keep it.
○
Fifth, start the engine while turning the steering wheel fully to the left.
○
The EPS warning indicator light (LED) ights up for 4 seconds and goes off.
If the EPS warning indicator light (LED) remains lit or blinks, turn the main switch OFF and repeat from fourth procedure again.
○
Sixth, free the hands from the steering wheel after indicator light goes off.
○
After 4 seconds, the EPS warning indicator light (LED) lights up.
○
Seventh, turn the steering wheel fully to the left and keep it, after indicator light lights up.
○
After 4 seconds, the EPS warning indicator light (LED) goes off.
○
Eighth, free the hands from the steering wheel after indicator light goes off.
○
After 4 seconds, the EPS warning indicator light (LED) blinks two times. This blink shows that the service code in the EPS ECU was erased.
If the EPS warning indicator light (LED) does not blink or lights up, turn the main switch OFF and repeat from fourth procedure again.
NOTE
○
The service code erase is same procedure as until eighth procedure.
STEERING 15-37
15-38 STEERING
EPS (Electric Power Steering) System
○
Ninth, wait for 5 seconds after indicator light blinks two times.
○
After 5 seconds, the EPS warning indicator light (LED) blinks three times. This blink shows that the EPS neutral position was registered.
If the EPS warning indicator light (LED) does not blink, turn the main switch OFF and repeat from fourth procedure again.
○
Lastly, wait for 1 second or more after indicator light blinks three times and turn the main switch OFF.
•
Disconnect the auxiliary lead from the terminals of the self-diagnosis system connector.
•
Start the engine and confirm that the EPS warning indicator light (LED) lights up for 1 second and goes off.
•
Confirm the EPS operates correctly.
EPS (Electric Power Steering) System
EPS Neutral Position Registration Flow Chart
STEERING 15-39
15-40 STEERING
EPS (Electric Power Steering) System
Power Supply Voltage Abnormal (Service Code
11,12)
○
The usable range of the power supply voltage is 10 V to
16 V.
•
Check the charging condition (see Alternator Operation
Inspection in the Electrical System chapter).
If the charging condition is normal, check the power supply voltage (see EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
EPS Neutral Position Unregistration (Service
Code 31)
○
This code appears in the following condition.
○
When the EPS ECU was replaced and the EPS neutral position is not registered in the new EPS ECU.
•
Register the EPS neutral position in the new EPS ECU
(see EPS Neutral Position Registration).
Current Sensor Inspection (Service Code 32)
○
The current sensor is built in the EPS ECU [A]. So, the current sensor itself can not be inspected.
•
•
Turn the main switch OFF.
Disconnect the EPS ECU and EPS motor connectors.
•
Check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead [C]
BK Lead [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
EPS (Electric Power Steering) System
FET (Field Effect Transistor) Inspection (Service
Code 33)
○
The FET is built in the EPS ECU [A]. So, the FET itself can not be inspected.
•
•
Turn the main switch OFF.
Disconnect the EPS ECU and EPS motor connectors.
•
Check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead Terminal [C]
BK Lead Terminal [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
Internal Relay Inspection (Service Code 34)
○
The relay function is included in the EPS ECU [A]. So, the relay function can not be inspected.
•
•
Turn the main switch OFF.
Disconnect the EPS ECU and EPS motor connectors.
•
Check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead Terminal [C]
BK Lead Terminal [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
STEERING 15-41
15-42 STEERING
EPS (Electric Power Steering) System
CPU (Central Processing Unit) Inspection (Service
Code 35)
○
The CPU is built in the EPS ECU [A]. So, the CPU itself can not be inspected.
•
Check the power supply voltage (see EPS ECU Power
Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
Direction Distinction Circuit Inspection (Service
Code 36)
○
The direction distinction circuit is built in the EPS ECU
[A]. So, the direction distinction circuit itself can not be inspected.
•
•
Turn the main switch OFF.
Disconnect the EPS ECU and EPS motor connectors.
•
Check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead Terminal [C]
BK Lead Terminal [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
Boosting Transformer Circuit Inspection (Service
Code 37)
○
The boosting transformer circuit is built in the EPS ECU
[A]. So, the boosting transformer circuit itself can not be inspected.
EPS (Electric Power Steering) System
•
•
Turn the main switch OFF.
Disconnect the EPS ECU and EPS motor connectors.
•
Check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead Terminal [C]
BK Lead Terminal [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
•
EPS Torque Sensor Inspection (Service Code 51)
•
Turn the main switch OFF.
Disconnect the EPS torque sensor connector [A].
•
Set the hand tester to the × 1Ω range and connect it to the EPS torque sensor connector [A].
Special Tool - Hand Tester: 57001-1394
•
Measure the EPS torque sensor resistance.
EPS Torque Sensor Resistance Inspection
Connections:
(I) Y/R Lead [B] ←→ BK/BL Lead [C]
(II) Y/BK Lead [D] ←→ BK/BL Lead [C]
Standard:
Both Connections: Any Reading Resistance
(reference 10
∼ 40 Ω at 20°C
(68°F))
If the reading is infinity (∞) Ω, replace the EPS unit (see
EPS Unit Removal/Installation).
STEERING 15-43
15-44 STEERING
EPS (Electric Power Steering) System
If the reading is in specification, disconnect the EPS ECU connectors and check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Torque Sensor Connector [B]
Y/BK Lead [C]
Y/R Lead [D]
BK/BL Lead [E]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, erase the service code with the service code erase mode and enter the self
-diagnosis mode again.
If the service code 51 appears again, replace the EPS
ECU (see EPS ECU Removal/Installation).
If the service code 51 disappears, it is a temporary failure.
•
EPS Motor Inspection (Service Code 61)
•
Remove the front cargo compartment (see Front Cargo
Compartment in the Frame chapter).
•
Turn the main switch OFF.
Disconnect the EPS motor connector [A].
[B] KAF950G9
∼ GC/HA
[C] KAF950GD
EPS (Electric Power Steering) System
•
Set the hand tester to the × 1Ω range and connect it to the EPS motor connector [A].
Special Tool - Hand Tester: 57001-1394
[B] KAF950G9
∼ GC/HA
[C] KAF950GD
•
Measure the EPS motor resistance.
EPS Motor Resistance Inspection
Connections: R Lead [D] ←→ BK Lead [E]
Standard
(KAF950G9
∼
GC/HA):
Any Reading Resistance (reference
0.15
∼ 0.19 Ω at 20°C (68°F))
Standard
(KAF950GD):
Any Reading Resistance (reference
0.13 Ω at 20°C (68°F))
If the reading is infinity (∞) Ω, replace the EPS unit (see
EPS Unit Removal/Installation).
If the reading is not infinity (∞) Ω, disconnect the EPS ECU connectors and check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead Terminal [C]
BK Lead Terminal [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, but the problem still exists, replace the EPS ECU (see EPS ECU Removal/Installation).
EPS Warning Indicator Light (LED) Removal
•
Remove:
Control Panel (see Control Panel Removal in the Frame chapter)
Nut [A]
EPS Warning Indicator Light (LED) [B]
STEERING 15-45
15-46 STEERING
EPS (Electric Power Steering) System
EPS Warning Indicator Light (LED) Inspection
•
Remove:
Front Cargo Compartment (see Front Cargo Compartment Removal in the Frame chapter).
Speedometer Cable Upper End [A]
•
Disconnect the EPS warning indicator light (LED) lead connectors.
R Lead [B]
BK/W Lead [C]
•
Using two auxiliary leads, connect the 12 V battery [A] to the EPS warning indicator light (LED) lead connectors as follows.
EPS Warning Indicator Light (LED) Inspection
Connections:
Battery (+) Terminal → R Lead
Battery (–) Terminal → BK/W Lead
If the EPS warning indicator light (LED) [A] does not light up, replace it (see EPS Warning Indicator Light (LED) Removal).
If the EPS warning indicator light (LED) lights up, check the following items.
Oil Pressure Switch
Oil Pressure Warning Indicator Light
If the above items are normal, check the wiring for continuity (Refer to the next wiring diagram).
EPS (Electric Power Steering) System
EPS Warning Indicator Light (LED) Circuit
STEERING 15-47
1. EPS ECU
2. EPS Warning Indicator Light (LED)
3. EPS Fuse 7.5 A
4. Oil Pressure Warning Indicator Light
5. Main Switch
6. Battery 12 V 52 Ah
7. Main Fuse 30 A
8. Fuse Box 2
9. Oil Pressure Switch
EPS ECU Removal
NOTICE
Never drop the EPS ECU, especially on a hard surface. Such a shock to the EPS ECU can damage it.
•
Remove the band [A] and open the ECU cover [B].
•
Disconnect the EPS ECU connectors [A].
15-48 STEERING
EPS (Electric Power Steering) System
•
Remove:
Right Glove Compartment (see Glove Compartment Removal in the Frame chapter)
Screws [A]
EPS ECU [B] (with Cover)
•
Remove the cover [A] from the EPS ECU.
EPS ECU Installation
•
Check that the rubber dampers [A], collars [B] and wellnut
[C] are in place on the frame.
If the rubber dampers are damaged or deteriorated, replace them.
○
When installing the rubber dampers, note the following.
○
Install the two rubber dampers of the front side so that the thin thickness side faces right side.
○
Do not apply a soap and water solution or rubber lubricant.
•
Install the cover [A] on the EPS ECU.
○
Install the cover so that open side faces left side.
•
Insert the projections [B] of the EPS ECU to the rubber dampers [C].
•
Tighten the screws securely.
•
When installing the band to the cover, note the following.
○
Pass the band through four slits [A] of the cover.
○
Bind the cover with the band securely.
If the EPS ECU was replaced, be sure to register the EPS neutral position(see EPS Neutral Position Registration).
NOTE
○
The EPS system can not function until the neutral position is registered in the new EPS ECU.
EPS (Electric Power Steering) System
EPS ECU Power Supply Voltage Inspection
•
Remove the band and open the cover (see EPS ECU
Removal).
•
Visually inspect the EPS ECU connectors [A].
If the connector is clogged with mud or dust, blow it off with compressed air.
If the connectors are normal, check the terminals of the
•
EPS ECU connectors.
Turn the main switch OFF.
•
Disconnect the EPS ECU connectors.
•
Visually inspect the terminals of the EPS ECU connectors
(main harness and EPS ECU).
If the terminals of the main harness connectors are damaged, replace the main harness.
If the terminals of the EPS ECU connectors are damaged, replace the EPS ECU.
If the terminals are normal, measure the power supply voltage of the EPS ECU.
NOTE
○
Be sure the battery is fully charged.
•
Set the hand tester [A] to the DC 25 V range and connect it to the main harness connectors [B].
Special Tool - Hand Tester: 57001-1394
EPS ECU Power Supply Voltage Inspection
Connections:
(I) Hand Tester (+) → W Lead Terminal [C]
Hand Tester (–) → Battery (–) Terminal
(II) Hand Tester (+) → BL/R Lead Terminal [D]
Hand Tester (–) → Battery (–) Terminal
Main Switch OFF:
Connection (I): Battery Voltage
Connection (II): 0 V
Engine Running:
Both Connections: Battery Voltage
If the reading is out of the specification, check the following.
EPS Fuse 40 A (see Fuse Inspection)
EPS Fuse 7.5 A (see Fuse Inspection)
Oil Pressure Switch
Oil Pressure Warning Indicator Light
Power Source Wiring and Ground Wiring (Refer to the next wiring diagram.)
STEERING 15-49
15-50 STEERING
EPS (Electric Power Steering) System
EPS ECU Power Source Circuit
1. EPS ECU
2. EPS Fuse 40 A
3. EPS Fuse 7.5 A
4. Oil Pressure Warning Indicator Light
5. Main Switch
EPS Motor Removal
NOTICE
Do not remove the EPS motor [A] from the EPS unit since it has been adjusted and set with precision at the factory.
[B] KAF950G9
∼ GC/HA
[C] KAF950GD
6. Battery 12 V 52 Ah
7. Main Fuse 30 A
8. Fuse Box 2
9. Oil Pressure Switch
EPS (Electric Power Steering) System
EPS Torque Sensor Removal
NOTICE
Do not remove the EPS torque sensor [A] from the
EPS unit since it has been adjusted and set with precision at the factory.
EPS Unit Removal
NOTICE
The EPS unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface. Be careful not to get water or mud on the EPS unit.
•
Remove:
Radiator (see Radiator Removal in the Cooling System chapter)
Left Radiator Side Cover (see Radiator Side Cover Removal in the Frame chapter)
Water Hoses [A]
•
Remove the steering gear assembly bracket bolts [B] and brackets [C].
•
Remove the mounting bolts [A] of the water pipe.
STEERING 15-51
•
Remove the universal joint clamp bolt [A].
If the clamp bolt becomes hard to turn, search the position that it can be easily turned while turning the steering wheel slowly.
•
Pull out the rubber boot [B] upward temporary.
15-52 STEERING
EPS (Electric Power Steering) System
•
Move the steering gear assembly, and pull off the shaft
[A] from the lower universal joint [B].
○
Lower the steering gear assembly, and then pull it forward.
•
Remove:
Rubber Boot [C]
Universal Joint Clamp Bolt [D]
Lower Universal Joint
•
Remove:
Steering Shaft (see Steering Wheel and Steering Shaft
Removal)
Universal Joint Clamp Bolt [A]
Upper Universal Joint [B]
•
Disconnect:
EPS Motor Connector [C]
Torque Sensor Connector [D]
[E] KAF950G9
∼ GC/HA
[F] KAF950GD
•
Remove:
Cotter Pin [A]
Pin [B]
Push Rod [C]
Spring [D]
•
Remove the EPS unit mounting bolts [A].
EPS (Electric Power Steering) System
•
Remove the EPS unit [A] downward while pushing down the brake pedal [B].
○
Insert the lower shaft to the hole of the under cover and avoid the upper shaft from the frame.
NOTICE
The EPS unit [A] has been adjusted and set with precision at the factory. Do not try to disassemble and repair the EPS unit.
[B] KAF950G9
∼ GC/HA
[C] KAF950GD
EPS Unit Installation
•
Check that the rubber dampers [A] and upper and lower collars [B] are in place on the frame.
If the rubber dampers are damaged or deteriorated, replace them.
○
When installing the rubber dampers, note the following.
○
Install the rubber dampers so that the thin thickness side faces up.
○
Do not apply a rubber lubricant.
•
Install the EPS unit so that the EPS torque sensor [A] faces upside.
•
Install the EPS unit mounting bolts [B] and tighten them temporary.
•
Install the lower universal joint [C] to the shaft of the EPS unit.
•
Install the universal joint clamp bolt [D] while aligning the notch on the shaft of the EPS unit with the clamp bolt hole on the lower universal joint, and tighten it temporary.
[E] KAF950G9
∼ GC/HA
[F] KAF950GD
STEERING 15-53
15-54 STEERING
EPS (Electric Power Steering) System
•
Install the rubber boot [A] on the shaft [B] of the steering gear assembly temporary.
•
Install the shaft of the steering gear assembly to the lower universal joint [C].
•
Install the universal joint clamp bolt [D] while aligning the notch on the shaft of the steering gear assembly with the clamp bolt hole on the lower universal joint, and tighten it temporary.
•
Install:
Rubber dampers [E]
Brackets [F]
•
Apply non-permanent locking agent to the steering gear assembly bracket bolts [G] and tighten them evenly.
Torque - Steering Gear Assembly Bracket Bolts: 52 N·m
(5.3 kgf·m, 38 ft·lb)
•
Tighten the EPS unit mounting bolts to the specified torque.
Torque - EPS Unit Mounting Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
[H] KAF950G9
∼ GC/HA
[I] KAF950GD
•
Install the rubber boot [A] so that the mark (F, Arrow) [B] faces forward.
•
Install the upper universal joint [A] to the shaft of the EPS unit [B].
•
Install the universal joint clamp bolt (lower) [C] while aligning the notch on the shaft of the EPS unit with the clamp bolt hole on the upper universal joint, and tighten it tem-
• porary.
Install the steering shaft [D] to the upper universal joint.
•
Install the universal joint clamp bolt (upper) [E] while aligning the notch on the steering shaft with the clamp bolt hole on the upper universal joint, and tighten it temporary.
•
Install the steering shaft mounting bolts [F], washers [G] and nuts [H].
•
Tighten all the universal joint clamp bolts to the specified torque.
Torque - Universal Joint Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
•
Install the washer [I] (KAF950GD).
[J] KAF950G9
∼ GC/HA
EPS (Electric Power Steering) System
•
Mount the steering wheel on the steering shaft temporarily.
•
Adjust the following items.
Steering Wheel Position (see Steering Wheel Position
Adjustment)
Steering Wheel Centering (see Steering Wheel Center-
• ing)
Install the removed parts (see appropriate chapters).
•
Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
Speed Sensor Removal/Installation
•
Refer to the Speed Sensor Removal/Installation in the
Electrical System chapter.
Speed Sensor Inspection
•
Refer to the Speed Sensor Inspection in the Electrical
System chapter.
If the speed sensor is normal, check the wiring for continuity (Refer to the next wiring diagram.).
Speed Sensor Circuit
STEERING 15-55
1. EPS ECU
2. Speed Sensor
3. Oil Pressure Warning Indicator Light
4. Main Switch
5. Battery 12 V 52 Ah
6. Main Fuse 30 A
7. Fuse Box 2
8. Oil Pressure Switch
15-56 STEERING
EPS (Electric Power Steering) System
EPS ECU Relay Removal/Installation
NOTICE
Never drop the relay, especially on a hard surface.
Such a shock to the relay can damage it.
•
Tilt up the seat.
•
Remove the EPS ECU relay [A] (BK/Y, W/Y, BR, W/BL) from the tongue and disconnect the connector.
•
Installation is the reverse of removal.
EPS ECU Relay Inspection
•
Remove:
EPS ECU Relay (see EPS ECU Relay Removal/Installation)
•
Connect the hand tester [A] and a 12 V battery [B] to the relay [C] as shown.
Special Tool - Hand Tester: 57001-1394
Testing Relay
Hand Tester Range: × 1 Ω
Criteria: When battery is connected →0 Ω
When battery is disconnected →∞ Ω
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
If the relay does not work as specified, replace the relay.
•
Diodes Removal/Installation
•
Tilt up the front seat and remove the diodes [A].
Installation is the reverse of removal.
EPS (Electric Power Steering) System
•
Diodes Inspection
Remove the diodes (see Diodes Removal/Installation).
•
Set the hand tester to the × 10 Ω or × 100 Ω range and connect it to the diode terminals to check the resistance in both directions.
Special Tool - Hand Tester: 57001-1394
The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the diode unit must be replaced.
NOTE
○
The actual meter reading varies with the meter used and the individual diode, but, generally speaking, the lower reading should be from the zero to one half the scale.
EPS Fuse 40 A Removal
NOTICE
Before removing the 40 A fuse [A], be sure to disconnect the battery cables to avoid electrical shock.
NOTE
○
The EPS fuse 40 A is installing with bolts to the EPS fuse box 1 [B].
•
Disconnect the battery cables (see Battery Removal in the
Electrical System chapter).
•
Lift up the EPS fuse box 1 [A] with rubber protector [B].
•
Slide the rubber protector [A].
•
Unlock the hooks to open the lids [B].
STEERING 15-57
15-58 STEERING
EPS (Electric Power Steering) System
•
Remove the terminal bolt [A] on both sides.
•
Unlock the hook to lift up the lid [A].
•
Pull the EPS fuse 40 A [B] straight out of the EPS fuse box 1 [C].
•
EPS Fuse 7.5 A Removal
•
Tilt up the front seat.
Unlock the hook to lift up the lid [A].
•
Pull the EPS fuse 7.5 A [A] straight out of the EPS fuse box 2 [B].
Fuse Installation
If a fuse fails during operation, inspect the EPS system to determine the cause, and then replace it with a new fuse of proper amperage.
○
For EPS fuse 40 A, after installing the lead terminals, tighten the terminal bolts securely.
Fuse Inspection
•
Remove the fuse (see EPS Fuse 7.5 A Removal/EPS
Fuse 40 A Removal).
•
Refer to the Fuse Inspection in the Electrical System chapter.
○
For EPS fuse 40 A, there is window for inspection in the upper surface.
FRAME 16-1
Frame
Table of Contents
16
16-2 FRAME
Exploded View
This page intentionally left blank.
FRAME 16-3
16-4 FRAME
Exploded View
Exploded View
No.
Fastener
1 Battery Holder Mounting Nuts
2 Stay Rod Rear Nut
3. KAF950G9
∼ GC/HA, CA and EUR Models
4. Apply grease on both surface.
5. Apply grease on the groove.
6. KAF950G9
∼ GC/HA
AD: Apply adhesive.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
FRAME 16-5
N·m
17
88
Torque kgf·m
1.7
9.0
ft·lb
13
65
Remarks
16-6 FRAME
Exploded View
Exploded View
No.
Fastener
1 Center Bar Mounting Bolts
2 Front Bar Mounting Bolts (Lower)
3 Front Bar Mounting Bolts (Upper)
4 Front Seat Bar Mounting Bolts
5 Rear Bar Mounting Bolts (Lower)
6 Rear Bar Mounting Bolts (Upper)
7 Rear Bar Mounting Nuts (Middle)
8 Rear End Subframe Mounting Nuts
9 Top Bar Mounting Bolts
10. Reflector (KAF950G9
∼ GB, CA Models)
11. Reflector (KAF950GC
∼, CA Models)
12. KAF950G9
∼ GC/HA
AD: Apply adhesive.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
FRAME 16-7
64
64
44
44
44
44
N·m
64
98
44
Torque kgf·m
6.5
10.0
4.5
6.5
6.5
4.5
4.5
4.5
4.5
47
47
32
32
32
32
ft·lb
47
72.3
32
Remarks
R
16-8 FRAME
Exploded View
Exploded View
No.
Fastener
1 Seat Belt Buckle Mounting Bolts
2 Seat Belt Mounting Bolts
3. KAF950G9, GA/HA
AD: Apply adhesive.
G: Apply grease.
R: Replacement Parts
FRAME 16-9
N·m
34
34
Torque kgf·m
3.5
3.5
ft·lb
25
25
Remarks
16-10 FRAME
Exploded View
Exploded View
No.
Fastener
1 Tail Gate Fixing Lever Screws
2 Screen Fixing Lever Screws
3. Fix the bolt to inside from outside.
4. 18 mm (0.71 in.)
5. Dampers
AD: Apply adhesive.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
FRAME 16-11
N·m
4.4
4.4
Torque kgf·m
0.45
0.45
ft·lb
39 in·lb
39 in·lb
Remarks
L
L
16-12 FRAME
Seats and Seat Belts
•
Front Seat Removal
Tilt up the seat [A].
•
Remove:
Seat Bracket Nuts [B]
Seat Brackets [C]
Seat
•
Remove:
Caps
Seat Back Mounting Nuts [A]
Seat Back [B]
[C] KAF950G9
∼ GA/HA
[D] KAF950GB
∼
Front Seat Installation
•
Installation is the reverse of removal, note the following.
○
Replace the seat bracket nuts and seat back mounting nuts with new ones.
○
Apply lithium grease (NLGI Grade No.2) to the inner surface of the seat bracket [A].
○
Be careful not to overtighten the seat bracket nuts. After tightening the nuts, the seat must be moved up and down smoothly.
○
Install the front seat back [A] so that its thicker side [B] faces downward.
○
Apply adhesive to the caps.
Seats and Seat Belts
•
When replacing the rear handle pad [A], install it on the seat bar [B] with adhesive agent.
○
Apply adhesive cement to 3 places: Both ends and center
(Length = 80 mm, 3.15 in.).
Slit [C]
•
Install the cover [D] so that its velcro side [E] faces downward.
•
Rear Seat Removal
•
Fold the rear seat and push its assembly into the stored position.
•
Tilt up the cargo bed.
Remove:
Pivot Bolt [A]
Nut [B]
Washers [C]
Rear Seat [D]
•
Remove:
Rear Seat Back Mounting Nuts [A]
Rear Seat Stay [B]
Rear Seat Back [C]
•
Remove:
Bottom Lever Bolts [A]
Bottom Lever [B] with Upper Lever [C]
•
Remove the circlip [A].
FRAME 16-13
16-14 FRAME
Seats and Seat Belts
•
Remove (Left Side only):
Circlip [A]
Spring [B] and Pin [C]
•
Separate the upper lever from the bottom lever.
•
Rear Seat Installation
Installation is the reverse of removal, note the following.
○
Replace the removed nuts with new ones.
○
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]
•
Remove:
Rear Seat Belt Mounting Bolts [A]
Rear Seat Belts [B]
Seats and Seat Belts
•
Remove:
Rear Seat Belt Buckle Mounting Bolts [A]
Rear Seat Belt Buckles [B]
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 installation angle is 40
∼ 60° [B].
•
Tighten:
Torque - Seat Belt Buckle Mounting Bolts: 34 N·m (3.5
kgf·m, 25 ft·lb)
○
Install the front seat belt buckles [A] so that their red buttons [B] face inside.
FRAME 16-15
16-16 FRAME
Control Panel
Control Panel Removal
•
Remove:
Front Cargo Compartment (see Front Cargo Compart-
• ment Removal)
Remove the bands [A] and clamp [B], and free the leads.
•
Disconnect:
Light Switch Lead Connector [C]
Oil Pressure Warning/Glow Plug Indicator Light Lead
Connector [D]
Speedometer Illumination Light Lead Connector [E]
Coolant Temperature Warning/Parking Brake Indicator
Light Lead Connector [F]
Power Steering Warning Light Lead Connector [G]
Hour Meter Lead Connector [H]
Main Switch Lead Connector [I]
Power Outlet Connector Lead Connector [J]
Fuel Gauge/Hour Meter Lead Connectors [K]
[L] KAF950G9
∼ GC/HA
[M] KAF950GD
•
Disconnect the horn switch lead connectors [A]
(KAF950GD).
•
Remove:
Bolts [A]
Speedometer Cable Upper End [B]
Speedometer [C] with Bracket
Control Panel
•
Remove the steering wheel (see Steering Wheel and
Steering Shaft Removal in the Steering chapter).
•
Remove the control panel mounting screws [A] and collars.
•
Open the glove compartment covers [A]
•
Remove the control panel [B]
•
Control Panel Installation
Installation is the reverse of removal, note the following.
○
Run the harness, cables and leads correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
Glove Compartment Removal
•
Remove:
Control Panel (see Control Panel Removal)
Screws [A]
Glove Compartment [B]
FRAME 16-17
16-18 FRAME
Front Cargo Compartment
•
Front Cargo Hood Removal
Tilt up the cargo hood [A].
•
Remove:
Cargo Hood Mounting Bolts [B] and washers
Cargo Hood
Front Cargo Hood Installation
If the dampers [A] are removed from the front cargo hood
[B], install them as follows.
0
∼ 5 mm (0 ∼ 0.20 in.) [C]
2
∼ 5 mm (0.08 ∼ 0.20 in.) [D]
•
Installation is the reverse of removal, note the following.
○
Contact the bracket [A] of the front cargo hood and the boss [B] of the arm [C].
Front Cargo Compartment
If the hook bracket was removed from the front cargo hood, install it as follows.
○
Tighten the bolts [A] while pushing the bracket [B] forward
[C].
Front Cargo Hood Cable Adjustment
•
Remove the front cargo compartment (see Front Cargo
Compartment Removal).
•
Loosen the adjuster mounting nuts [A], and slides the adjuster as shown in the figure.
20.5
∼ 21.5 mm (0.81 ∼ 0.85 in.) [B]
•
Tighten the adjuster mounting nuts securely.
Front Cargo Compartment Removal
•
Remove:
Front Fenders (see Front Fender Removal)
Coolant Reserve Tank (see Coolant Reserve Tank Removal in the Cooling System chapter)
•
Remove:
Screws [A] and Collars
Tapping Screw [B] and Collar
•
Remove:
Side Mounting Bolts [A] (Left and Right)
Front Cargo Compartment [B]
Front Cargo Compartment Installation
•
Installation is the reverse of removal, note the following parts size.
Screws [A] [L = 16 mm (0.63 in.)] and Collars [L = 4 mm
(0.16 in.)]
Screws [B] [L = 22 mm (0.87 in.)] and Collars [L = 6 mm
(0.24 in.)]
Tapping Screw [C] [L = 16 mm (0.63 in.)] and Collar [L =
4 mm (0.16 in.)]
FRAME 16-19
16-20 FRAME
Cargo Bed
Cargo Bed Removal
•
Remove the rear fender assembly (see Rear Fender Assembly Removal).
•
Open the clamps [A] and disconnect the tail/brake light lead connectors [B] (left and right).
•
Remove (Left and Right):
Bolts [C]
Tail/Brake Light Assemblies [D]
•
Open the steal clamp on the cargo bed and free the lead.
•
Unlock the hooks [A].
•
Raise the rear seat and push it toward the front seat back to store.
•
Remove (Left and Right):
Snap Pins [A]
Cargo Bed Mounting Pins [B]
•
Remove the cargo bed.
Cargo Bed Installation
•
Installation is the reverse of removal, note the following.
○
Apply lithium grease (NLGI Grade No.2) to the cargo bed mounting pins.
○
Check that the following are in place on the cargo bed and frame.
Cargo Bed Rubber Dampers [A]
Frame Rubber Dampers [B]
Tail Gate Pivot Rubber Dampers (Left and Right)
Cargo Bed
•
When the cargo bed is disassembled, note the following when installing the plates and tail gate.
○
Be sure the clearance [A] between the back end of the carrier [B] and the bottom of the tail gate [C] is more than
2 mm (0.079 in.) as shown in the figure (left and right).
○
Be sure the clearance [A] between the plate end [B] and the tail gate end [C] is less than 5 mm (0.197 in.) as shown in the figure (left and right).
FRAME 16-21
16-22 FRAME
Front, Center and Rear Bars
Front Bar Removal
•
Remove:
Front Fenders (see Front Fender Removal)
Front Bar Mounting Bolts [A] and Washers (Upper)
Front Bar Mounting Bolts [B] (Lower)
Front Bar [C]
Front Bar Installation
•
Tighten:
Torque - Front Bar Mounting Bolts (Upper): 44 N·m (4.5
kgf·m, 32 ft·lb)
Front Bar Mounting Bolts (Lower): 98 N·m (10,0 kgf·m, 72,3 ft·lb)
•
Install the front fenders (see Front Fender Installation).
•
Rear Bar Removal
Tilt up the cargo bed.
•
Remove:
Rear Side Covers (see Rear Side Cover Removal)
Rear Bar Mounting Bolts [A] and Washers (Upper)
•
Remove:
Air Duct [A]
Rear Bar Mounting Bolts [B] and Nuts (Middle)
Rear Bar Mounting Bolts [C], Washers and Nuts (Lower)
•
Remove:
Air Duct [A]
Rear Bar Mounting Bolts [B] and Nuts (Middle)
Rear Bar Mounting Bolts [C], Washers and Nuts (Lower)
Rear Bar [D]
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.
•
Be sure the rubber dampers [A] are in position.
○
The rubber damper rear end and bracket rear end are on the same line [B].
Front [C]
○
When installing the right middle pipe [A], tighten the bolts and nuts as shown in the figure.
Front [B]
•
Replace the rear bar mounting nuts (lower) with new ones.
•
Tighten:
Torque - Rear Bar Mounting Bolts (Upper): 44 N·m (4.5
kgf·m, 32 ft·lb)
Rear Bar Mounting Nuts (Middle): 44 N·m (4.5
kgf·m, 32 ft·lb)
Rear Bar Mounting Bolts (Lower): 64 N·m (6.5
kgf·m, 47 ft·lb)
•
Install the removed parts (see appropriate chapter).
Center Bar Removal
•
Remove:
Rear Bar (see Rear Bar Removal)
Top Bar Mounting Bolts [A] and Washers
Top Bars [B]
FRAME 16-23
16-24 FRAME
Front, Center and Rear Bars
•
Remove:
Seat Bar Mounting Bolts [A] and Washers
Seat Bar [B] with Front Seat Back
•
Remove:
Front Bar Mounting Bolts (Upper Side only)
Center Bar Mounting Bolts [A], Washers and Nuts
Center Bar [B]
•
Center Bar Installation
Replace the center bar mounting nuts with new ones.
•
Tighten:
Torque - Center Bar Mounting Bolts: 64 N·m (6.5 kgf·m, 47 ft·lb)
Top Bar Mounting Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)
Seat Bar Mounting Bolts: 64 N·m (6.5 kgf·m, 47 ft·lb)
•
Route the fuel tank breather hose [A] and install its end into the steel clamp [B] on the center bar as shown in the figure.
•
Install the removed parts (see appropriate chapter).
Cargo Bed Latch Position Inspection
•
Cargo bed must be latched securely on the cargo bed or the rear seat hooks [A] without rattling.
Latch [B]
If there is rattling or not snug enough, adjust the latch positions.
Front, Center and Rear Bars
•
Cargo Bed Latch Position Adjustment
Release the mounting bolts [A].
•
Reposition the latch to the suitable place by sliding within the ellipse bolt holes.
•
Retighten the mounting bolts.
NOTE
○
Adjustment must be made on both sides.
FRAME 16-25
16-26 FRAME
Guard
Front Guard Removal
•
Remove:
Screws [A] and Collars (KAF950G9
∼ GC/HA)
Front Guard Cover [B] (KAF950G9
∼ GC/HA)
•
Remove (Left and Right):
Front Guard Bolts [A] (Upper)
Front Guard Bolts [B] and Nuts (Lower)
•
Remove the front guard [C].
[D] KAF950G9
∼ GC/HA
[E] KAF950GD
•
Front Guard Installation
Installation is the reverse of removal, note the following.
○
Replace the nuts (lower) with new ones.
Fenders
Front Fender Removal
•
Remove:
Screws [A] and Collars
Rivets [B]
•
Clear the hook portion [C] from the slot and remove the front fender [D].
Front Fender Installation
○
Check that the clip-nuts [A] are in place as shown in the figure.
•
Insert the hook portion [A] into the slot [B] of the front fender.
•
Install the front fender, note the following parts [A] [B] [C] size.
Screws [A] [L = 16 mm (0.63 in.)] and Collars [L = 4 mm
(0.16 in.)]
Screw [B] [L = 22 mm (0.87 in.)] and Collar [L = 6 mm
(0.24 in.)]
Tapping Screw [C] [L = 20 mm (0.79 in.)] and Collar [L =
9.5 mm (0.37 in.)]
Quick Rivets [D]
Rear Fender Assembly Removal
•
Remove:
Screws [A] and Collars
Rear Fender [B]
FRAME 16-27
16-28 FRAME
Fenders
•
Remove:
Tapping Screws [A]
Bolt [B], Collar and Nut
Rear Fender Stay [C]
•
Remove:
Bolts [A], Collars and Nuts
Rear Fender Inner Cover [B]
Covers
•
Front Cover Removal
Tilt up the front cargo hood.
•
Remove:
Front Fenders (see Front Fender Removal)
Front Guard (see Front Guard Removal)
Screws [A] and Collars (Left and Right)
Bolts [B] and Washers (Left and Right)
•
Disconnect the head light connecters [A] (Left and Right).
•
Remove the front cover [B] with head lights assembly.
•
Front Cover Installation
Installation is the reverse of removal, note the following.
○
Check that the clip-nuts [A] (left and right) are in place as shown in the figure.
○
Attach the rubber damper [A] of the bracket to the dent
[B] of the front cover.
Front Fender Inner Cover Removal
•
Remove:
Front Fender (see Front Fender Removal)
Tapping Screw [A] and Collar
Quick Rivets [B]
Front Fender Inner Cover [C] (Middle)
FRAME 16-29
16-30 FRAME
Covers
•
Remove:
Tapping Screws [A] and Collars
Quick Rivets [B]
Front Fender Inner Cover [C] (Front)
•
Remove:
Middle Cover (see Middle Cover Removal)
Tapping Screws [A] and Collars
Screws [B]
Nut [C] and Collar
Quick Rivets [D]
Front Fender Inner Cover [E] (Rear)
•
Front Fender Inner Cover Installation
Installation is the reverse of removal, note the following.
○
Replace the nut with a new one.
Radiator Side Cover Removal
•
Remove:
Tapping Screws [A]
Bolt [B]
•
Remove the front guard mounting nut [C] temporary, and remove the radiator side cover [D].
Front Side Cover Removal
•
Remove:
Screws [A] and Collars
Quick Rivets [B]
Front Side Cover [C]
Covers
Front Side Cover Installation
•
Install the front side cover, note the following parts [A] [B] size.
Screw [A] [L = 16 mm (0.63 in.)] and Collar [L = 4 mm
(0.16 in.)]
Screw [B] [L = 16 mm (0.63 in.)] and Collar [L = 6 mm
(0.24 in.)]
Quick Rivets [C]
Rear Side Cover Removal
•
Remove:
Screws [A] and Collars
Tapping Screws [B] and Collars
Quick Rivets [C]
Rear Side Cover [D]
Rear Side Cover Installation
○
Check that the clip-nuts [A] are in place as shown in the figure.
•
Install the rear side cover, note the following parts [B] [C]
[D] size.
Screws [B] [L = 16 mm (0.63 in.)] and Collars [L = 4 mm
(0.16 in.)]
Screw [C] [L = 16 mm (0.63 in.)] and Collar [L = 6 mm
(0.24 in.)]
Tapping Screws [D] [L = 16 mm (0.63 in.)] and Collars [L =
4 mm (0.24 in.)]
Quick Rivets [E]
Middle Cover Removal
•
Remove:
Tapping Screws [A] and Collars
Quick Rivets [B]
Screw [C] and Collar
Middle Cover [D]
FRAME 16-31
16-32 FRAME
Covers
•
Middle Cover Installation
Install is the reverse of removal, note the following.
○
Check that the clip-nuts [A] are in place as shown in the figure.
Flap Cover Removal
•
Remove:
Screws [A] and Collars
Quick Rivets [B]
Flap Cover [C]
Flap and Flap Stay Removal
•
Remove:
Rear Side Cover (see Rear Side Cover Removal)
Flap Cover (see Flap Cover Removal)
Screw [A] and Collar
Quick Rivet [B]
Flap [C]
•
Remove:
Flap Stay Mounting Bolts [A]
Flap Stay [B]
Floor Center Panel Removal
•
Remove:
Screws [A]
Quick Rivets [B]
Front Seat Lower Cover (Front) [C]
Covers
•
Remove:
Bolts [A]
Throttle Pedal [B]
•
Remove:
Tapping Screws [A]
Front Floor Center Panel [B]
•
Remove:
Tapping Screws [A]
Front Seat Lower Cover Rear [B]
•
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
Tapping Screws [A]
Tapping Screw [B] and Washer
Rear Seat Lower Cover [C]
•
Remove:
Tapping Screws [A]
Rear Floor Center Panel [B]
FRAME 16-33
16-34 FRAME
Covers
•
Floor Center Panel Installation
Installation is the reverse of removal, note the following.
○
Install the bushing [A] so that the cut side [B] faces to the throttle pedal.
Rear End Subframe
Rear End Subframe Removal
•
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Transmission Case (see Transmission Case Removal in the Transmission chapter)
Rear End Subframe Mounting Bolts [A] and Nuts
Rear End Subframe [B]
Rear End Subframe Installation
•
Replace the rear end subframe mounting nuts with new ones.
•
Tighten:
Torque - Rear End Subframe Mounting Nuts: 44 N·m (4.5
kgf·m, 33 ft·lb)
FRAME 16-35
ELECTRICAL SYSTEM 17-1
Electrical System
Table of Contents
Exploded View...................................
Wiring Diagram (KAF950G9, GA/HA) 17-12
Wiring Diagram (KAF950GB, GC).....
Wiring Diagram (KAF950GD) ............
Specifications ....................................
Special Tools .....................................
Parts Location....................................
Precautions........................................
Electrical Wiring.................................
Wiring Inspection .........................
Battery ...............................................
Battery Removal ..........................
Battery Installation .......................
(Conventional Type Battery)......
Inspection (Conventional Type
Battery)......................................
(Conventional Type Battery)......
Initial Charging (Conventional
Type Battery).............................
(Sealed Type Battery) ...............
Ordinary Charging........................
(Conventional Type Battery)......
Alternator ...........................................
Alternator Removal ......................
Alternator Installation ...................
Alternator Disassembly ................
Alternator Assembly.....................
Alternator Operational Inspection 17-36
Stator Coil Inspection...................
Rotor Coil Inspection....................
Slip Ring Cleaning .......................
Slip Ring Diameter .......................
Carbon Brush Length...................
Rectifier Inspection ......................
Regulator Inspection ....................
Alternator Ball Bearing Inspection 17-38
Electric Starter System ......................
Starter Motor Removal.................
Starter Motor Installation..............
Starter Motor Disassembly...........
Starter Motor Assembly ...............
Carbon Brush Inspection .............
Yoke Inspection............................
Brush Plate Inspection .................
Commutator Cleaning/Inspection.
Armature Inspection.....................
Pinion Gear Inspection.................
Starter Switch Inspection .............
Starter Circuit Relay Inspection ...
Preheating System ............................
Glow Plug Removal .....................
Glow Plug Installation ..................
Glow Plug Inspection ...................
Preheating Timer Inspection ........
Glow Plug Relay Inspection .........
Glow Plug Relay Installation ........
Fuel Cut Solenoid ..............................
Fuel Cut Solenoid ........................
Fuel Cut Solenoid Inspection .......
Radiator Fan......................................
Radiator Fan Circuit Inspection....
Radiator Fan Motor Inspection.....
Radiator Fan Breaker Inspection .
Radiator Fan Relay Inspection.....
Meter, Gauge.....................................
Speedometer Removal ................
Speedometer Installation .............
(KAF950GD) .............................
Installation (KAF950GD) ...........
(KAF950GD) .............................
(KAF950GD) .............................
Lighting System .................................
Headlight Beam Adjustment ........
Headlight Bulb Replacement .......
Tail/Brake Light Replacement ......
Light Switch Bulb Replacement ...
Indicator Light Bulb Replacement 17-59
Replacement .............................
Headlight Removal.......................
Headlight Installation....................
Reverse Light Switch Installation
(EUR Model) .............................
Switches and Sensors .......................
Brake Light Switch Inspection......
Radiator Fan Switch Inspection ...
Inspection..................................
Switch Inspection .........................
Speed Sensor Removal ...............
Speed Sensor Installation ............
17
17-2 ELECTRICAL SYSTEM
Speed Sensor Inspection.............
Fuses.................................................
Fuse Removal..............................
Fuse Installation...........................
50 A Fuse Removal .....................
Fuse Installation...........................
Fuse Inspection............................
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ELECTRICAL SYSTEM 17-3
17-4 ELECTRICAL SYSTEM
Exploded View
Exploded View
No.
Fastener
1 Alternator Adjusting Bracket Bolts
2 Alternator Mounting Bolt
3 Alternator Pulley Locknut
4 Starter Motor End Cover Screws
5 Starter Motor Mounting Bolts
6 Starter Motor Through Bolts
G: Apply grease.
R: Replacement Parts
ELECTRICAL SYSTEM 17-5
N·m
20
39
11
1.5
39
9.3
Torque kgf·m
2.0
4.0
1.1
0.15
4.0
0.95
ft·lb
15
29
97 in·lb
13 in·lb
29
82 in·lb
Remarks
17-6 ELECTRICAL SYSTEM
Exploded View
Exploded View
No.
Fastener
1 Battery Holder Mounting Nuts
2 Connecting Plate Nuts
3 Coolant Temperature Switch
4 Glow Plugs
5 Neutral Switch
6 Oil Pressure Switch
7 Radiator Fan Switch
8 Radiator Fan Switch
9. KAF950G9
∼ GC/HA, Other than US Model
10. Fuel Cut Solenoid Connector
11. Glow Plug Relay
12. Light Switch
13. Preheating Timer
14. Radiator Fan Breaker
15. Radiator Fan Relay
16. Starter Circuit Relay
17. Horn Button
18. KAF950GB
∼
19. KAF950G9, GA/HA
20. KAF950GD
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.
17
15
14
23
25
N·m
17
1.2
27
ELECTRICAL SYSTEM 17-7
Torque kgf·m
1.7
0.12
2.8
1.7
1.5
1.4
2.3
2.5
ft·lb
13
11 in·lb
20
13
11
10
17
18
Remarks
L
SS
17-8 ELECTRICAL SYSTEM
Exploded View
Exploded View
No.
Fastener
1 Speed Sensor Bolt
2. KAF950G9
∼ GC/HA
3. Ground Lead Connection
4. Horn
5. Horn Switch Contact
6. Steering Gear Assembly
7. Hour Meter
8. Fuel Gauge/Hour Meter
9. Speedometer
R: Replacement Parts
TO: Apply transmission oil.
ELECTRICAL SYSTEM 17-9
N·m
8.8
Torque kgf·m
0.90
ft·lb
78 in·lb
Remarks
17-10 ELECTRICAL SYSTEM
Exploded View
EUR Model
Exploded View
1. Reverse Light
2. Reverse Light Switch
ELECTRICAL SYSTEM 17-11
17-12 ELECTRICAL SYSTEM
Wiring Diagram (KAF950G9, GA/HA)
Wiring Diagram (KAF950G9, GA/HA)
ELECTRICAL SYSTEM 17-13
17-14 ELECTRICAL SYSTEM
Wiring Diagram (KAF950GB, GC)
Wiring Diagram (KAF950GB, GC)
ELECTRICAL SYSTEM 17-15
17-16 ELECTRICAL SYSTEM
Wiring Diagram (KAF950GD)
Wiring Diagram (KAF950GD)
ELECTRICAL SYSTEM 17-17
17-18 ELECTRICAL SYSTEM
Specifications
Item
Battery
Capacity
Voltage
Conventional Type:
Gross Weight
Electrolyte Volume
Electrolyte Level
Specific Gravity
Sealed Type:
Gross Weight
Electrolyte Volume
Alternator
Type
Fan Belt Deflection
Output Voltage
Output Amperage (no load)
Output Amperage (load)
Stator Coil Resistance
Rotor Coil Resistance
Slip Ring Diameter
Carbon Brush Length (Projected
Portion)
Electric Starter System
Starter Motor:
Carbon Brush Length
Commutator Diameter
Preheating System
Glow Plug Resistance
Meter, Gauge
Fuel Level Gauge Resistance:
Full Position
Empty Position
Switches and Sensors
Brake Light Switch Timing
Radiator Fan Switch Resistance:
Rising Temperature
Falling Temperature
12 V 52 Ah
12.6 V or more
14.5 kg (32.0 lb)
3.8 L (232 cu in.)
Between upper and lower level
1.265 at 20°C (68°F)
13.4 kg (29.5 lb)
3.03 L (185 cu in.)
Three-phase (built-in regulator/rectifier)
9.5
∼ 11.5 mm (0.37 ∼ 0.45 in.) at 98 N
(10 kgf, 22 lb)
13.3
∼ 14.8 V at 25°C (77°F)
10 A or less
20 A or more
0.2 Ω or less
2.8
∼ 3.0 Ω
14.4 mm (0.57 in.)
10.5 mm (0.41 in.)
– – –
– – –
– – –
– – –
– – –
– – –
– – –
14.0 mm (0.55 in.)
8.4 mm (0.33 in.)
15.5 mm (0.61 in.)
30 mm (1.18 in.)
About 0.1
∼ 5.0 Ω
9
∼ 11 Ω
119
∼ 121 Ω
Standard
ON after 10 mm (0.39 in.) of pedal travel
From OFF to ON at 86
∼ 90°C (187 ∼
194°F)
From ON to OFF at 81
∼ 85°C (178 ∼
185°F)
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
Service Limit
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
11.0 mm (0.43 in.)
29 mm (1.14 in.)
– – –
– – –
– – –
– – –
– – –
– – –
ELECTRICAL SYSTEM 17-19
Specifications
Coolant Temperature Switch
Resistance:
Rising Temperature
Falling Temperature
From OFF to ON at 112
∼ 118°C (234
∼ 244°F)
From ON to OFF within 10°C (50°F) of
“ON” temperature
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
– – –
– – –
17-20 ELECTRICAL SYSTEM
Special Tools
Socket Wrench, Hex 22:
57001-1236
Hand Tester:
57001-1394
Parts Location
Hour Meter [A]
Main Switch [B]
Power Outlet Connector [C]
Fuel Gauge/Hour Meter [D]
[E] KAF950G9
∼ GC/HA
[F] KAF950GD
ELECTRICAL SYSTEM 17-21
Light Switch [A]
Oil Pressure Warning Indicator Light [B]
Coolant Temperature Warning Indicator Light [C]
Speedometer [D]
Parking Brake Indicator Light [E]
Glow Plug Light [F]
Horn Button [G]
[H] KAF950G9
∼ GC/HA
[I] KAF950GD
Starter Circuit Relay [A]
Preheating Timer [B]
Radiator Fan Relay [C]
Glow Plug Relay [D]
Parking Brake Light Switch [E]
17-22 ELECTRICAL SYSTEM
Parts Location
Fuse Box [A]
Frame Ground Terminal [B]
Radiator Fan Breaker [C]
Battery 12 V 52 Ah [D]
50 A Fuse [E]
Starter Motor [A]
Alternator [B]
Glow Plugs [C]
Coolant Temperature Switch [D]
Engine Ground Terminal [E]
Oil Pressure Switch [A]
Fuel Cut Solenoid Valve [B]
Neutral Switch [C]
Horn [A]
Radiator Fan Switch [B]
Radiator Fan [C]
Brake Light Switch [D]
Speed Sensor [A]
Precautions
There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below.
○
Do not reverse the battery cable connections. This will burn out the diodes in the electrical parts.
○
Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
○
The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
○
To prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connections when the main switch is ON, or while the engine is running.
○
Because of the large amount of current, never keep the main switch turned to the start position when the starter motor will not turn over, or the current may burn out the starter motor windings.
○
Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis ground.
○
Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was brought on by some other item or items, they too must be repaired or replaced, or the replacement part will soon fail again.
○
Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation.
○
Measure coil and winding resistance when the part is cold
(at room temperature).
ELECTRICAL SYSTEM 17-23
17-24 ELECTRICAL SYSTEM
Electrical Wiring
Wiring Inspection
•
Visually inspect the wiring for signs of burning, fraying, etc.
If any wiring is poor, replace the damaged wiring.
•
Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
• is damaged, replace it.
Check the wiring for continuity.
○
Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
○
Connect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001-1394
○
Set the tester to the ×1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness if necessary.
Battery
○
In this model, two batteries are prepared.
Conventional Type Battery [A] (KAF950G9
∼ GC/HA,
Other Than US Model)
The caps [B] can be removed.
ELECTRICAL SYSTEM 17-25
Sealed Type Battery [A] (US Model and KAF950GD)
•
Battery Removal
Tilt up the front seat.
•
Remove the front seat lower cover rear (see Floor Center
Panel Removal in the Frame chapter).
•
Slide the positive terminal cover [A] out.
•
Disconnect the battery negative (–) cable and lead [B] first, and then the positive (+) cable and leads [C].
•
Remove:
Battery Holder Mounting Nuts [D]
Battery Holder [E]
•
Remove the battery [F] backward [G].
Battery Installation
•
Check that the rubber dampers [A] on the battery case [B] and battery holder [C] are properly in place.
○
Install the battery case [A] so that the long side [B] faces right side [C].
17-26 ELECTRICAL SYSTEM
Battery
•
Install the O-rings [A] from the opposite end of the threads
[B] of each battery holder rod [C] to protect the O-rings.
NOTE
○
Do not set the O-ring on the threads of the rod.
•
Install:
Battery Holder Rod (Front Side)
Pipe [A]
For Conventional Type Battery:
For Sealed Type Battery:
206.5 mm (8.13 in.)
199.5 mm (7.85 in.)
Battery Holder [B]
○
Install the holder so that the short side [C] of the holder faces forward.
•
Tighten the battery holder mounting nut [D] lightly.
•
Put the battery on the case so that the positive terminal
[A] faces right side.
•
Install:
Battery Holder [B]
Battery Holder Rod (Rear Side)
Pipe [C] and Nut [D]
•
Tighten:
Torque - Battery Holder Mounting Nuts: 17 N·m (1.7 kgf·m,
13 ft·lb)
•
Connect the four leads on the positive lead connector [A] as shown in the figure.
Red/White, Red [B]
Blue, White [C]
Black/White [D]
Red (Alternator Lead) [E]
○
Install the four leads almost parallel to the positive cable so that they can be covered with the cap easily.
•
Connect the positive (+) cable and leads first, and then connect the negative (–) cable and lead (black and black/yellow).
•
Put a light coat of grease on the terminals to prevent corrosion.
•
Cover the positive terminals with the positive terminal cover.
Battery
(for Sealed Type Battery)
•
Confirm the position of the battery handle [A] is below the holder [B] and cables [C] as shown in the figure.
ELECTRICAL SYSTEM 17-27
Electrolyte Level Inspection (Conventional Type
Battery)
•
Refer to the Electrolyte Level Inspection (Conventional
Type Battery) in the Periodic Maintenance chapter.
Electrolyte Specific Gravity Inspection
(Conventional Type Battery)
•
Refer to the Electrolyte Specific Gravity Inspection (Conventional Type Battery) in the Periodic Maintenance chapter.
Charging Condition Inspection (Conventional
Type Battery)
•
Refer to the Charging Condition Inspection (Conventional
Type Battery) in the Periodic Maintenance chapter.
Initial Charging (Conventional Type Battery)
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.
NOTICE
Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than-normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting
If the temperature of the electrolyte rises above
45°C (113°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
17-28 ELECTRICAL SYSTEM
Battery
•
Remove:
Battery (see Battery Removal)
Filler Caps (see Electrolyte Level Inspection (Conventional Type Battery))
WARNING
Electrolyte contains sulfuric acid which is harmful to skin, eyes, and clothing.
Wear eye protection and rubber gloves.
If spillage occurs on body or clothing, rinse at once with water for at least 15 minutes.
•
Place the carton [A] on a flat surface as shown in the figure, pull the tab back to edge of the carton.
•
Pull out the hose [B] and cut off end of the hose.
•
Fill each cell [A] until the electrolyte level rises to bottom
[B] of the split ring [C] of the vent well.
NOTICE
Do not fill into the split [D]. Do not overfill.
•
After filling cells, wait five to ten minutes.
If necessary to bring electrolyte to proper level, add the additional electrolyte.
WARNING
Neutralize any residue with baking soda.
Rinse empty package with large quantities of water.
Destroy empty package to prevent accidents!
•
Place the strips of filler caps [A] loosely over the filler ports.
•
Charge the battery at 15 amps until specific gravity of electrolyte rises to 1.250 and a temperature of 15.5°C
(60°F) (Both conditions must be met.).
Battery
If violent gassing or spewing occurs, reduce the charge rate.
NOTICE
Never allow a battery to get HOT to the touch. If the battery is excessively hot to the touch, discontinue charging immediately.
Allow the battery to cool down before monitoring gravities or continuing charge.
•
After charging, if the electrolyte level has fallen, refill the battery with the electrolyte to upper level.
•
Fit the filler caps [A] firmly.
ELECTRICAL SYSTEM 17-29
Charging Condition Inspection (Sealed Type
Battery)
Battery charging condition can be checked by measuring battery terminal voltage.
•
Remove the battery (see Battery Removal).
NOTICE
Be sure to disconnect the negative (−) cable first.
•
Measure the battery terminal voltage.
NOTE
○
Measure with a digital voltmeter [A] which can be read to one decimal place voltage.
If the reading is below the specified, refreshing charge is required.
Battery Terminal Voltage
Standard: 12.6 V or more
17-30 ELECTRICAL SYSTEM
Battery
Ordinary Charging
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.
NOTICE
Always remove the battery from the vehicle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the vehicle.
Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting.
Higher-than-normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting.
If the temperature of the electrolyte rises above
45°C (113°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
•
Remove the battery (see Battery Removal).
NOTE
○
Never attempt to charge a frozen battery.
○
Allow it to warm up to room temperature before charging.
○
Never leave a battery on a trickle charger longer than
48 hours. Serious damage to the battery will occur.
(Conventional Type Battery)
•
Charge the battery with a current of 1 to 1.5 amps until the specific gravity rises to 1.250 and temperature reaches
15.5°C (60°F).
•
Refer to the Battery Charging Time Table for the charging.
Battery
•
Check the electrolyte level after charging.
If the electrolyte level is low add water only after initial activation.
WARNING
Electrolyte contains sulfuric acid which is harmful to skin, eyes, and clothing.
Wear eye protection and rubber gloves.
If spillage occurs on body or clothing, rinse at once with water for at least 15 minutes.
•
Turn the charger off or plug it, then disconnect it from the battery.
If the battery condition indicates that it is not fully charged, additional charging time is necessary.
(Sealed Type Battery)
•
Charge the battery according to the battery terminal voltage.
WARNING
This battery is sealed battery type. Never remove seal sheet or cap [A] even at charging. Never add water. Charge with current and time as stated below.
•
Refer to the Battery Charging Time Table for the charging.
Battery Charging Time Table at 27°C (80°F)
Battery
Voltage
12.6 V
12.4 V
State of
Charge
100%
75%
Charging Time to Full Charge
2 A 6 A 10 A
405 min.
Full Charge
135 min.
81 min.
12.2 V
12.0 V
50%
25%
810 min.
270 min.
1 215 min.
405 min.
162 min.
243 min.
•
11.8 V 0% 1 620 min.
540 min.
Determine battery condition after charging.
324 min.
○
Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below.
Criteria
12.6 V or higher
12.0
∼ 12.6 V or lower
12.0 V or lower
Judgement
Good
Charge insufficient → Recharge
Unserviceable → Replace
Battery Testing Chart (Conventional Type Battery)
Once battery is in an adequate state of charge the following load test procedure will be valid. The load test is undertaken to determine if the battery has adequate electrical performance or if it has to be replaced.
Important: This procedure is valid only it the battery is at or above the state of check specified in STEP 2.
ELECTRICAL SYSTEM 17-31
17-32 ELECTRICAL SYSTEM
Battery
Battery Testing Chart
Alternator
Alternator Removal
•
Remove:
Fan Belt Cover (see Cooling Fan Belt Inspection in the
Periodic Maintenance chapter)
Alternator Terminal Locknut [A]
Alternator Lead Connector [B]
ELECTRICAL SYSTEM 17-33
•
Remove:
Alternator Adjusting Bracket Bolt [A]
Alternator Mounting Bolt [B]
Alternator [C]
Alternator Installation
•
Clean the alternator legs and alternator bracket where the alternator is grounded.
•
Adjust the fan belt deflection (see Cooling Fan Belt Inspection in the Periodic Maintenance chapter).
•
Tighten:
Torque - Alternator Adjusting Bracket Bolts: 20 N·m (2.0
kgf·m, 15 ft·lb)
Alternator Mounting Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Alternator Disassembly
•
Remove:
Terminal Nut [A]
Insulator [B]
End Cover Bolts [C]
End Cover [D]
•
Remove:
Brush Holder [A]
Regulator [B]
Rectifier Screws [C]
17-34 ELECTRICAL SYSTEM
Alternator
•
Straighten the stator coil wires [A].
•
Remove the rectifier [B].
•
Use the following, loosen the pulley locknut [A].
Socket Wrench [B] (Special Tool: 57001-1236)
Deep Socket Wrench [C]
Special Tool - Socket Wrench, Hex 22: 57001-1236
•
Remove:
Pulley Locknut
Pulley [D]
•
Remove the collar [A].
•
Remove:
Housing Cover Mounting Bolts [A] and Nuts [B]
Housing Cover [C]
•
Remove:
Rotor [A]
Alternator Housing [B]
Alternator
•
Remove:
Bearing Holder [A]
Ball Bearing [B]
○
To remove the ball bearing [A], use a suitable puller.
ELECTRICAL SYSTEM 17-35
•
Alternator Assembly
Press the bearing and bearing holder onto the rotor shaft.
•
Straighten the stator coil wires.
•
Install:
Housing Cover [A]
Housing Cover Mounting Bolts [B] and Nuts [C]
•
•
Install the rectifier [A].
•
Bend the stator coil wire ends [B] around the screw holes.
Tighten the rectifier screws.
•
Install:
Regulator
Brush Holder
End Cover
Insulator
Terminal Nut
17-36 ELECTRICAL SYSTEM
Alternator
•
Install:
Collar
Pulley [A]
•
Use the following, tighten the locknut.
Socket Wrench [B] (Special Tool: 57001-1236)
Deep Socket Wrench [C]
Special Tool - Socket Wrench, Hex 22: 57001-1236
Torque - Alternator Pulley Locknut: 11 N·m (1.1 kgf·m, 97 in·lb)
Alternator Operational Inspection
•
Check the battery condition.
Conventional Type Battery (see Charging Condition
Inspection (Conventional Type Battery) in the Periodic
Maintenance chapter)
Sealed Type Battery (see Charging Condition Inspection
(Sealed Type Battery))
NOTE
○
Always check the battery condition before condemning the alternator. The battery must be fully charged in order to conduct accurate alternator inspection.
•
Check the wiring (see Wiring Inspection).
•
Warm up the engine to bring the components up to their normal operating temperatures.
•
Stop the engine.
•
Remove the 30 A main fuse (see Fuse Removal).
•
Connect the hand tester [A] (range DC 25 V) and ammeter
[B] (range DC 40 A, after the engine start) as shown in the figure.
Battery [C]
50 A Fuse [D]
Alternator [E]
Load [F]
•
Measure the alternator output voltage and amperage at 2
000 rpm with the light switch turned OFF.
Alternator Output Voltage
Standard: 13.3
∼ 14.8 V at 25°C (77°F)
Alternator Output Amperage (no load)
Standard: 10 A or less
•
•
Stop the engine.
Install the 30 A main fuse (see Fuse Installation).
•
Measure the alternator output voltage and amperage at 2
000 rpm with the light switch turned ON.
Alternator Output Voltage
Standard: 13.3
∼ 14.8 V at 25°C (77°F)
Alternator Output Amperage (load)
Standard: 20 A or more
If the readings are not within the specified range, check the alternator.
Alternator
Stator Coil Inspection
•
Connect the hand tester (× 1 Ω range) between the coil wires and read the tester.
Special Tool - Hand Tester: 57001-1394
If the tester does not read as specified, replace the alternator frame.
Stator Coil Resistance: 0.2 Ω or less
•
Using the highest hand tester range, measure the resistance between the stator coil core and each of the coil windings.
If there is any reading at all, the stator coil winding has a short and the alternator housing must be replaced.
Rotor Coil Inspection
•
Connect the hand tester (× 1 Ω range) between the slip rings [A] and read the tester.
Special Tool - Hand Tester: 57001-1394
If the tester does not read as specified, replace the rotor
[B].
Rotor Coil Resistance: 2.8
∼ 3.0 Ω
•
Using the highest tester range, measure the resistance between the rotor shaft and each of the slip rings.
If there is any reading at all, the rotor coil has a short and must be replaced.
Slip Ring Cleaning
•
Visually inspect the slip ring for dirt or pitting.
If necessary, smooth the slip ring with No. 300
∼ No. 500 emery cloth.
Slip Ring Diameter
•
Measure the diameter of the slip rings.
If the measurement is less than the service limit, replace the rotor [A].
Slip Ring Diameter
Standard: 14.4 mm (0.57 in.)
Service Limit: 14.0 mm (0.55 in.)
ELECTRICAL SYSTEM 17-37
Carbon Brush Length
•
Measure the length [A] that both carbon brushes that stick out of the holder.
If either one is worn down to less than the service limit, replace it.
Carbon Brush Length (Projected Portion)
Standard: 10.5 mm (0.41 in.)
Service Limit: 8.4 mm (0.33 in.)
17-38 ELECTRICAL SYSTEM
Alternator
•
Rectifier Inspection
Set the hand tester to the 1 kΩ range.
•
Zero the hand tester, and connect it to each terminal to check the resistance in both directions.
○
The resistance should be low in one direction and more than ten times as much in the other direction. If the rectifier [A] shows low or high in both directions, the rectifier is defective and the rectifier must be replaced.
NOTE
○
The actual meter reading varies with the meter used and the individual rectifier, but, generally speaking, the lower reading should be from zero to one half the scale.
NOTICE
If a megger or a meter with a large-capacity battery is used, the rectifier will be damaged.
Regulator Inspection
•
Set the hand tester to the 1 kΩ range.
Special Tool - Hand Tester: 57001-1394
•
Check the resistance between F [A] and B [B] terminals in both directions.
○
The resistance should be low in one direction and more than ten times as much in the other direction.
If the reading shows low or high in both directions, the regulator [C] is defective and must be replaced.
Alternator Ball Bearing Inspection
NOTICE
Do not disassemble the alternator for bearing inspection since disassembling the alternator damages the bearings.
•
Turn the alternator rotor shaft back and forth while checking for play, roughness or binding of bearings.
If bearing play, roughness, or binding is found, disassemble the alternator and replace the bearings.
Alternator
Alternator Circuit
ELECTRICAL SYSTEM 17-39
1. Main Switch
2. Battery
3. Fusible Link 50 A
4. Load
5. Alternator
6. Stator Coil
7. Rotor
8. Rectifier
9. Regulator
10. Main Fuse 30 A
11. Fuse Box 2
17-40 ELECTRICAL SYSTEM
Electric Starter System
•
Starter Motor Removal
Tilt up the cargo bed.
•
Remove:
Starter Motor Lead Connector [A]
Starter Motor Cable [B]
Starter Motor Mounting Bolts [C]
Starter Motor [D]
Starter Motor Installation
•
Clean the mating surface [A] of the starter motor and the end plate where the starter motor is grounded.
•
Apply liquid gasket [A] to the mating surface as shown in the figure.
Sealant - Three Bond: 1207F
•
Install the starter motor and tighten the mounting bolts.
Torque - Starter Motor Mounting Bolts: 39 N·m (4.0 kgf·m,
29 ft·lb)
Starter Motor Disassembly
•
Remove:
Field Coil Cable Nut [A]
Field Coil Cable [B]
•
Remove:
Starter Motor Through Bolts [A]
Yoke [B]
Electric Starter System
•
Remove:
End Cover Screws [A] and O-rings
End Cover [B]
•
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]
Rollers [B]
ELECTRICAL SYSTEM 17-41
17-42 ELECTRICAL SYSTEM
Electric Starter System
•
Remove the return spring [A].
Starter Motor Assembly
•
Apply grease to the following parts.
Retainer and Rollers
Starter Clutch
Steel Ball
Return Spring
Armature Bearing
Grease - Denso No. 50 Grease or Equivalent (Esso Beacon
325)
•
Install the retainer [A] and rollers [B] on the drive end cover shaft [C].
○
Face the opening side [D] of the retainer to the magnetic switch assy.
•
Install:
Starter Clutch [A]
Idle Gear [B]
•
Install:
Steel Ball
Return Spring
Drive End Cover and Screws
Electric Starter System
•
Install the positive brushes [A] on the brush plate [B] with needle nose pliers.
○
Pull the springs [C] and brushes, and hold the brushes with the springs.
•
Install the armature.
ELECTRICAL SYSTEM 17-43
•
Install:
End Cover [A]
End Cover Screws [B] and O-rings
•
Tighten:
Torque - Starter Motor End Cover Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
•
Install the yoke [A] on the magnetic switch [B].
•
Tighten:
Torque - Starter Motor Through Bolts: 9.3 N·m (0.95 kgf·m,
82 in·lb)
•
Install the field coil cable and tighten the nut securely.
Carbon Brush Inspection
•
Measure the carbon brush length [A].
If the brush length is less than the service limit, replace the brush assembly.
Carbon Brush Length
Standard: 15.5 mm (0.61 in.)
Service Limit: 11.0 mm (0.43 in.)
Yoke Inspection
•
Measure the resistance between the carbon brush and the wire terminal [A].
Special Tool - Hand Tester: 57001-1394
If there is not close to 0 Ω, the field coils have an open.
Replace the yoke.
•
Measure the resistance between the carbon brush and the yoke body [B].
If there is any reading, the yoke has a short. Replace the yoke.
17-44 ELECTRICAL SYSTEM
Electric Starter System
Brush Plate Inspection
•
Measure the resistance between the carbon brush and the brush plate [A].
Special Tool - Hand Tester: 57001-1394
If there is not close to 0 Ω, the brush plate has an open.
Replace the brush plate.
•
Measure the resistance between the brush plate and the
(+) brush holder [B].
If there is any reading, the brush plate has a short. Replace the brush plate.
Commutator Cleaning/Inspection
•
Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.
•
Measure the diameter [A] of the commutator [B].
Replace the starter motor with a new one if the commutator diameter is less than the service limit.
Commutator Diameter
Standard: 30 mm (1.18 in.)
Service Limit: 29 mm (1.14 in.)
Armature Inspection
•
Using the × 1 Ω range of the hand tester, measure the resistance between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
If there is a high resistance or no reading (∞) between any two segments, a winding is open. Replace the starter motor.
•
Using the highest range of the hand tester, measure the resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short.
Replace the starter motor.
NOTE
○
Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
Electric Starter System
Pinion Gear Inspection
•
Turn the pinion gear by hand. It should turn clockwise freely [A], but should not turn freely counterclockwise [B].
If the pinion gear does not operate as it should or if there is any worn or damaged part, replace it.
ELECTRICAL SYSTEM 17-45
Starter Switch Inspection
•
Connect a 12 V battery to the starter switch [A] as shown in the figure.
○
Connect the battery negative (–) cable [B] first and then the positive lead to the terminal in the connector [C].
If the switch does not work as specified, the switch is defective. Replace the starter switch.
Testing Switch
Criteria: When battery is connected →
Pinion gear must move outward quickly.
When battery is disconnected →
Pinion gear must return quickly.
Starter Circuit Relay Inspection
•
Remove:
Mounting Rivets [A]
Screws [B]
Front Seat Lower Cover Left [C]
•
Remove:
Starter Circuit Relay Connector [A]
Starter Circuit Relay [B]
17-46 ELECTRICAL SYSTEM
Electric Starter System
•
Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown in the figure.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Hand Tester Range: × 1 Ω
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
Electric Starter Circuit
1. Starter Circuit Relay
2. Main Switch
3. Neutral Switch
4. Battery
5. Starter Motor
6. Main Fuse 30 A
7. Fuse Box 2
8. Starter Relay Fuse 30 A
9. Fuse Box 1
Preheating System
•
Glow Plug Removal
•
Tilt up the cargo bed.
Remove the caps [A].
•
Remove:
Connecting Plate Nuts [A]
Connecting Plate [B]
Glow Plug Lead [C]
•
Remove the glow plug [A].
Glow Plug Installation
•
Tighten:
Torque - Glow Plugs: 17 N·m (1.7 kgf·m, 13 ft·lb)
Connecting Plate Nuts: 1.2 N·m (0.12 kgf·m, 11 in·lb)
Glow Plug Inspection
•
Using the × 1 Ω range of the hand tester, measure the resistance between the terminal [A] and the housing [B] of the glow plug.
Special Tool - Hand Tester: 57001-1394
If the tester does not read as specified, replace the glow plug.
Glow Plug Resistance: About 0.1
∼ 5.0 Ω
NOTE
○
Be careful not to apply the battery voltage to the glow plug directly.
○
Be careful not to scratch the heater section [C].
ELECTRICAL SYSTEM 17-47
17-48 ELECTRICAL SYSTEM
Preheating System
Preheating Timer Inspection
•
Remove the front seat lower cover left (see Starter Relay
Inspection).
•
Check that the main switch is turned OFF, and connect the hand tester [A] to the preheating timer [B] as follows.
Special Tool - Hand Tester: 57001-1394
Hand Tester Range: DC 25 V
Hand Tester (+) Lead → Black Lead Terminal
Hand Tester (–) Lead → Ground
•
When the main switch is turned ON, the reading should show less than 1.8 V during 5 seconds.
If the preheating timer does not work, replace the timer.
Glow Plug Relay Inspection
•
Remove:
Front Seat Lower Cover Left (see Starter Relay Inspection)
Mounting Bolt [A] and Nut
Glow Plug Relay [B]
Glow Plug Relay Lead Connectors [C]
•
Connect the hand tester [A] and 12 V battery [B] to the glow plug relay [C] as shown in the figure.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Hand Tester Range: × 1 Ω
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
Relay Coil Terminals [85] and [86]
Relay Switch Terminals [30] and [87]
Glow Plug Relay Installation
•
Connect the leads to the glow plug relay terminals as follows.
Black Lead (Tag No. 85) → to Terminal No. 85 [A]
Brown Lead (Tag No. 86) → to Terminal No. 86 [B]
→ to Terminal No. 87 [C] Black/White Lead (Tag
No. 87)
Black/White Lead (Tag
No. 30)
→ to Terminal No. 30 [D]
Preheating System
Preheating System Circuit
ELECTRICAL SYSTEM 17-49
1. Neutral Switch
2. Starter Circuit Relay
3. Glow Plug Relay
4. Glow Plug Light
5. Main Switch
6. Glow Plugs
7. Battery
8. Main Fuse 30 A
9. Preheating Timer Fuse 5 A
10. Fuse Box 2
11. Starter Relay Fuse 30 A
12. Fuse Box 1
13. Preheating Timer
17-50 ELECTRICAL SYSTEM
Fuel Cut Solenoid
Fuel Cut Solenoid
The fuel cut solenoid [A] is in the fuel injection pump.
When the main switch is turned to the “START” position, the fuel solenoid is energized and the solenoid valve [B] lifts against the spring [C] and opens the fill port [D] to the pressure chamber.
When the switch is returned to the “ON” position, after the engine has started, the current flows through a resistor to the solenoid, reducing the current slightly but maintaining enough energy to hold the valve open.
Turning the main switch to the “OFF” position shuts off the current to the solenoid. With no current to hold the valve, the spring forces the valve to close the fill port, thus shutting off the fuel supply and the engine.
Fuel Cut Solenoid Inspection
•
When the main switch is turned ON, check that the fuel cut solenoid makes a clicking sound (operating sound).
If the fuel injection pump does not click, replace it, or consult a reliable fuel injection pump repair shop (ex. Denso
Service Station).
Fuel Cut Solenoid Circuit
1. Main Switch
2. Battery
3. Main Fuse 30 A
4. Preheating Timer Fuse 5 A
5. Fuse Box 2
6. Fuel Cut Solenoid
7. Fuel Injection Pump
Radiator Fan
•
Radiator Fan Circuit Inspection
•
Remove the front cargo compartment (see Front Cargo
Compartment Removal in the Frame chapter).
•
Disconnect the leads from the radiator fan switch.
Using an auxiliary lead [A], connect the radiator fan switch leads.
If the radiator fan rotates, inspect the radiator fan switch.
If the radiator fan does not rotate, inspect the following.
Wiring and Connectors
Radiator Fan Breaker (see Radiator Fan Breaker Inspection)
Radiator Fan Motor (see Radiator Fan Motor Inspection)
Radiator Fan Relay (see Radiator Fan Relay Inspection)
Radiator Fan Motor Inspection
•
Disconnect the fan motor lead connector [A] from the harness.
•
Using two auxiliary leads, supply battery power to the fan motor.
If the fan does not rotate at this time, the fan motor is defective and must be replaced.
Radiator Fan Motor Leads
Red : Battery (+)
Black
: Battery (–)
•
Radiator Fan Breaker Inspection
Tilt up the front seat.
•
Remove:
Battery Cables (see Battery Removal)
Radiator Fan Breaker [A]
ELECTRICAL SYSTEM 17-51
•
Inspect the breaker for operation.
•
Connect:
12 V Battery [A]
0.3 Ω Resistance [B]
Radiator Fan Breaker [C]
Switch [D]
If the circuit in the breaker will not open within 60 seconds, replace the breaker.
17-52 ELECTRICAL SYSTEM
Radiator Fan
Radiator Fan Relay Inspection
•
Remove:
Front Seat Lower Cover Left (see Starter Relay Inspection)
Radiator Fan Relay Lead Connector [A]
Radiator Fan Relay [B]
•
Connect the hand tester [A] and 12 V battery [B] to the radiator fan relay [C] as shown in the figure.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Hand Tester Range: × 1 Ω
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
Radiator Fan
Radiator Fan Circuit
ELECTRICAL SYSTEM 17-53
1. Radiator Fan Relay
2. Radiator Fan Switch
3. Radiator Fan
4. Battery
5. Radiator Fan Breaker
17-54 ELECTRICAL SYSTEM
Meter, Gauge
Speedometer Removal
•
Remove:
Front cargo compartment (see Front Cargo Compartment Removal in the Frame chapter).
Band [A]
•
Disconnect the speedometer illumination lead connector
[B].
•
Remove:
Speedometer Cable [A]
Meter Bracket Bolts [B] and washers
•
Remove the speedometer [A] backward [B].
•
Remove:
Speedometer screws [A] and washers [B]
Speedometer bracket [C] and washers [D]
Speedometer [E]
Remove the rubber dampers as necessary.
•
Remove the rubber dampers as necessary.
Speedometer Installation
•
Install the following parts as shown in the figure.
Rubber Dampers [A]
Washers [B]
Speedometer Bracket [C]
Speedometer Screws [D]
Speedometer [E]
•
Install the two rubber dampers of the speedometer bracket so that its thicker side faces meter side.
•
Apply a non-permanent locking agent to the threads of the speedometer screws.
Meter, Gauge
Fuel Gauge/Hour Meter Removal (KAF950GD)
•
Remove the front cargo compartment (see Front Cargo
•
Compartment Removal in the Frame chapter).
•
Clear the clips [A] and remove the stopper [B].
Remove the fuel gauge/hour meter [C].
ELECTRICAL SYSTEM 17-55
•
Fuel Gauge/Hour Meter Installation (KAF950GD)
Installation is the reverse of removal.
○
Run the harness, cables and leads correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
Fuel Gauge (LED) Inspection (KAF950GD)
•
Remove the fuel gauge/hour meter (see Fuel Gauge/Hour
Meter Removal).
[1] Battery (–)
[2] Battery (+)
[4] Fuel Level Gauge
•
Using the auxiliary leads, connect the 12 V battery to the fuel gauge/hour meter connector as follows.
Battery Positive (+) Terminal to Terminal [2]
Battery Negative (–) Terminal to Terminal [1]
•
Connect the variable rheostat [A] to the terminal [4].
•
Check that the number of segments [A] matches the resistance value of the variable rheostat.
○
The number of fuel gauge segments increases or decreases one by one every 10 seconds.
Variable Rheostat
Resistance (Ω)
10
120
Display Segments
10
1 (blink)
If the fuel gauge display function does not work, replace the fuel gauge/hour meter.
17-56 ELECTRICAL SYSTEM
Meter, Gauge
Fuel Level Gauge Inspection (KAF950GD)
•
Remove:
Fuel Level Gauge (see Fuel Level Gauge Removal in the Fuel System chapter)
•
Check that the float moves up and down smoothly without binding. It should go down under its own weight.
If the float does not move smoothly, replace the fuel level gauge.
Float in Full Position [A]
Float in Empty Position [B]
•
Using a tester, measure the resistance across the terminals in the fuel level gauge lead connector.
Special Tool - Needle Adapter Set: 57001-1457
If the tester readings are not as specified, or do not change smoothly according as the float moves up and down, replace the fuel level gauge.
Fuel Level Gauge Resistance
Standard: Full position: 9
∼ 11 Ω
Empty position: 119
∼ 121 Ω
Fuel Level Gauge Circuit (KAF950GD)
1. Main Switch
2. Fuel Gauge
3. Fuel Level Gauge
4. Battery
5. Fuse Box 1
6. Main Fuse 30 A
Lighting System
Headlight Beam Adjustment
•
Turn the adjusting screw [A] on each headlight in or out to adjust the headlight vertically.
ELECTRICAL SYSTEM 17-57
Headlight Bulb Replacement
•
Remove the front cover (see Front Cover Removal in the
Frame chapter).
•
Turn the headlight bulb [A] counterclockwise [B] and pull out the bulb from the headlight.
•
Replace the headlight bulb.
•
Fit the projections [A] of the bulb in the hollows [B] of the headlight.
•
Turn the headlight bulb [A] clockwise [B].
•
Install the front cover (see Front Cover Installation in the
Frame chapter).
Tail/Brake Light Replacement
•
Remove:
Screws [A]
Tail/Brake Light Lens [B]
17-58 ELECTRICAL SYSTEM
Lighting System
•
Push and turn the bulb [A] counterclockwise [B] and remove it.
NOTICE
Do not use bulbs rated for greater wattage than the specified value.
•
Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
○
Turn the bulb about 15°.
•
Install the tail/brake light lens.
○
Be careful not to overtighten the lens mounting screws.
Light Switch Bulb Replacement
•
Remove the front cargo compartment (see Front Cargo
Compartment Removal in the Frame chapter).
•
Turn the socket [A] counterclockwise, and pull it with the bulb.
•
Pull the bulb [A] out of the socket.
NOTICE
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
Do not use bulb rated for greater wattage than the specified value.
•
Insert the new bulb in the socket.
•
Align the projections [A] of the socket with the recesses
[B] in the switch body, and turn the socket clockwise.
Lighting System
Indicator Light Bulb Replacement
Oil Pressure Warning Indicator Light [A]
Coolant Temperature Warning Indicator Light [B]
Parking Brake Indicator Light [C]
Glow Plug Light [D]
ELECTRICAL SYSTEM 17-59
•
Remove:
Light Assembly [A]
Lens [B]
•
Roll the rubber [A] up and pull the bulb [B] out of the socket.
NOTICE
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
Do not use bulb rated for greater wattage than the specified value.
•
Install:
New Bulb
Lens [A]
Light Assembly [B]
Speedometer Illumination Bulb Replacement
•
Remove the front cargo compartment (see Front Cargo
Compartment Removal in the Frame chapter).
•
Pull the socket [A] with the bulb from the speedometer.
17-60 ELECTRICAL SYSTEM
Lighting System
•
Pull the bulb [A] out of the socket [B].
NOTICE
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
Do not use bulb rated for greater wattage than the specified value.
•
Insert the new bulb in the socket [A].
•
Install the socket into the speedometer [B].
Headlight Removal
•
Remove:
Front Cover (see Front Cover Removal in the Frame chapter)
Bolts [A] (KAF950F9
∼ FB)
Screws [A] (KAF950FC
∼)
Screws [B]
•
Headlight Installation
○
Check that the clip-nuts [A] are in place as shown in the figure.
•
For the KAF950F9
∼ FB, tighten the bolts and screws.
•
For the KAF950FC, tighten the screws.
Install the front cover (see Front Cover Installation in the
Frame chapter).
•
Reverse Light Switch Installation (EUR Model)
Put the transmission shift lever in the REVERSE position.
•
Install the reverse light switch bracket [A] on the reverse shift lever so that the switch rod [B] contacts the boss [C] and the clearance is 1
∼ 2 mm (0.04 ∼ 0.08 in.) [E].
•
Tighten the shift shaft lever clamp bolt [D] securely.
Lighting System
Lighting System Circuit
ELECTRICAL SYSTEM 17-61
1. Speedometer Illumination
2. Oil Pressure Warning Indicator Light
3. Coolant Temperature Warning Indicator
Light
4. Parking Brake Indicator Light
5. Light Switch Indicator Light
6. Light Switch
7. Main Switch
8. Headlights
9. Brake Light Switch
10. Coolant Temperature Switch
11. Parking Brake Light Switch
12. Oil Pressure Switch
13. EPS Fuse 7.5 A
14. EPS Warning Indicator Light (LED)
15. EPS ECU
16. Reverse Light Switch (EUR Model)
17. Reverse Light (EUR Model)
18. Tail/Brake Lights
19. Battery
20. Main Fuse 30 A
21. Fuse Box 2
17-62 ELECTRICAL SYSTEM
Switches and Sensors
Brake Light Switch Inspection
•
Refer to the Brake Light Switch Inspection in the Periodic
Maintenance chapter.
Radiator Fan Switch Inspection
•
Remove the radiator fan switch (see Radiator Fan Switch
Removal in the Cooling System chapter).
•
Suspend the fan switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.
•
Suspend an accurate thermometer [B] in the coolant, so that the sensitive portions [C] are located in almost the same depth.
NOTE
○
The switch and thermometer must not touch the container sides or bottom.
•
Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently.
•
Using the hand tester, measure the internal resistance of the switch across the terminals at the temperatures shown in the table.
Special Tool - Hand Tester: 57001-1394
If the hand tester does not show the specified values, replace the switch.
Radiator Fan Switch Resistance
Rising Temperature:
From OFF to ON at 86
∼ 90°C (187 ∼ 194°F)
Falling Temperature:
From ON to OFF at 81
∼ 85°C (178 ∼ 185°F)
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
Switches and Sensors
Coolant Temperature Switch Inspection
•
Remove the coolant temperature switch (see Coolant
Temperature Switch Removal in the Cooling System chapter).
•
Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.
•
Suspend an accurate thermometer [B] in the coolant, so that the sensitive portions [C] are located in almost in the same depth.
NOTE
○
The switch and thermometer must not touch the container sides or bottom.
•
Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently.
•
Using the hand tester, measure the internal resistance of the switch across the connector and the body at the temperatures shown in the table.
Special Tool - Hand Tester: 57001-1394
If the hand tester does not show the specified values, replace the switch.
Coolant Temperature Switch Resistance
Rising Temperature:
From OFF to ON at 112
∼ 118°C (234 ∼ 244°F)
Falling Temperature:
From ON to OFF within 10°C (50°F) of “ON” temperature
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
ELECTRICAL SYSTEM 17-63
17-64 ELECTRICAL SYSTEM
Switches and Sensors
Switch Inspection
•
Using a hand tester, check to see that only the connections shown in the table have continuity (about zero ohms).
Special Tool - Hand Tester: 57001-1394
○
For the main switch, light switch, brake light switch, parking brake light switch, and neutral switch, refer to the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it with a new one.
Horn Switch Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.
Reverse Light Switch Connections (EUR Model)
Speed Sensor Removal
NOTICE
Never drop the speed sensor, especially on a hard surface. Such a shock to the sensor can damage it.
•
Drain the transmission oil (see Transmission Oil Change in the Periodic Maintenance chapter).
•
Disconnect the speed sensor lead connector [A].
•
Remove:
Bolt [B]
Speed Sensor [C]
Switches and Sensors
•
Speed Sensor Installation
Replace the O-ring [A] with a new one.
•
Apply transmission oil to the O-ring.
•
Tighten
Torque - Speed Senor Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
ELECTRICAL SYSTEM 17-65
•
Speed Sensor Inspection
Remove the speed sensor (see Speed Sensor Removal).
•
Connect the speed sensor connector [A] with the battery
[B], 10 kΩ resistor [C] and hand tester [D] as shown in the figure.
•
Set the tester to the DC 25 V range.
Special Tool - Hand Tester: 57001-1394
•
Trace [A] each side of the speed sensor surface with the screwdriver.
○
Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed sensor.
17-66 ELECTRICAL SYSTEM
Fuses
•
Fuse Removal
•
Tilt up the front seat.
Unlock the hook [A] and remove the fuse box cover [B].
•
Pull the fuses [A] straight out of the fuse box.
Fuse Installation
•
Install the fuse cover [A] so that the yellow mark [B] faces left side of the vehicle.
•
50 A Fuse Removal
Tilt up the front seat.
•
Unlock the stopper [A] and pull the 50 A fuse [B] straight out of the fuse box.
Fuse Installation
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
•
Install the fuse box fuses on the original position as specified on the lid.
Fuses
•
Fuse Inspection
Remove the fuse (see Fuse Removal).
•
Inspect the fuse element.
○
For 50 A fuse, there is window for inspection in the upper surface.
If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTE
○
If the engine is operated under the condition which the battery needs refreshing charge, a main fuse may blow out due to a mass current flows to the battery.
NOTICE
When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause damage to wiring and components.
ELECTRICAL SYSTEM 17-67
APPENDIX 18-1
Appendix
Table of Contents
18
18-2 APPENDIX
Cable, Wire, and Hose Routing
KAF950G9
∼ GC/HA
Cable, Wire, and Hose Routing
1. Accessory Terminal
2. Main Switch
3. Band
4. EPS ECU
5. Hour Meter
6. EPS Warning Indicator Light (LED)
7. Glow Plug Light
8. Parking Brake Indicator Light
9. Speedometer Cable
10. Speedometer Illumination
11. Coolant Temperature Warning Indicator Light
12. Oil Pressure Warning Indicator Light
13. Light Switch
14. Band
15. To Left Headlight
16. Band
17. EPS Motor Connector
18. Band
19. EPS Torque Sensor Connector
20. Band
21. To Right Headlight
22. Front
23. Detail A
24. Accessory Terminals
25. Band
26. Front
27. Clamp
28. Detail B
29. Detail C
30. 25 mm (0.98 in.)
31. To Horn Switch
APPENDIX 18-3
18-4 APPENDIX
Cable, Wire, and Hose Routing
KAF950GD
Cable, Wire, and Hose Routing
1. Accessory Terminal
2. Main Switch
3. Band
4. EPS ECU
5. Fuel Gauge/Hour Meter
6. EPS Warning Indicator Light (LED)
7. Glow Plug Light
8. Parking Brake Indicator Light
9. Speedometer Cable
10. Speedometer Illumination
11. Coolant Temperature Warning Indicator Light
12. Oil Pressure Warning Indicator Light
13. Horn Button
14. Light Switch
15. Band
16. To Left Headlight
17. Band
18. EPS Motor Connector
19. Band
20. EPS Torque Sensor Connector
21. Band
22. To Right Headlight
23. Front
24. Detail A
25. Accessory Terminals
26. Band
27. Front
28. Clamp
29. Detail B
30. Detail C
31. 25 mm (0.98 in.)
32. To Horn Switch
APPENDIX 18-5
18-6 APPENDIX
Cable, Wire, and Hose Routing
1. Radiator Fan Motor
2. Radiator Fan Motor Lead
3. The band must be located in exact position as shown in the figure.
4. Radiator Fan Switch Lead
5. 50 mm (1.97 in.)
6. Horn Lead
7. Clamp
8. Front Final Gear Case Breather Hose
9. Clamp
10. Front Final Gear Case
11. The cooling hose should be under the bracket of the frame.
12. Front
13. View from Top
Cable, Wire, and Hose Routing
APPENDIX 18-7
1. Hold the right brake hose with the harness.
2. Right Brake Hose
3. Brake Master Cylinder
4. Keep the brake hose away from the EPS unit.
5. Install the clamp in this direction.
6. Left Brake Hose
7. Front
18-8 APPENDIX
Cable, Wire, and Hose Routing
1. EPS 40 A Fuse
2. EPS 7.5 A Fuse
3. Clamp
4. Band
5. EPS Self-diagnosis System Connector
6. Band
7. Band
8. Band
Cable, Wire, and Hose Routing
APPENDIX 18-9
1. Differential Shift Cable
2. 2WD/4WD Shift Cable
3. Hi/Low Shift Cable
4. Transmission Shift Cable
5. Throttle Cable
6. Clamp
7. To Engine
8. Nut
9. Torque Converter Case
10. Torque Converter Inner Cover
11. Front
12. Viewed from Top
18-10 APPENDIX
Cable, Wire, and Hose Routing
KAF950G9 (Early Model)
1. Breather Tube (L = 1 480 mm (58.3 in.))
2. Brake Hose
3. Coolant Reserve Tank
4. Band
5. Clamp
6. Brake Pipe
7. Front
8. Route cooling hose under frame pipe.
9. Pass the cooling hose through the hole of the bracket on the frame.
Cable, Wire, and Hose Routing
KAF950G9 (Late Model) and Later Model
APPENDIX 18-11
1. Breather Tube (L = 1 100 mm (43.3 in.))
2. Brake Hose
3. Push the tube into the hole of case storage.
4. Clamp
5. Band
6. Front
18-12 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
Cable, Wire, and Hose Routing
KAF950G9
∼ GC/HA
APPENDIX 18-13
1. Right Parking Brake Cable
2. Left Parking Brake Cable
3. Clamp
4. Rubber Tube
5. Cap
6. Washer
7. Left Brake Hose
8. Right Brake Hose
9. Right Leaf Spring
10. Left Leaf Spring
11. 50 mm (1.97 in.)
12. Band
13. Front
14. View A
18-14 APPENDIX
Cable, Wire, and Hose Routing
KAF950GD
APPENDIX 18-15
Cable, Wire, and Hose Routing
1. Right Parking Brake Cable
2. Left Parking Brake Cable
3. Clamp
4. Rubber Tube
5. Cap
6. Washer
7. Left Brake Hose
8. Right Brake Hose
9. Right Leaf Spring
10. Left Leaf Spring
11. 50 mm (1.97 in.)
12. Band
13. Front
14. View A
15. Detail B
16. Corrugated Tubes
17. Install the corrugated tubes so that the slits face inside of the vehicle to prevent the breather tube and brake hose being damaged by the edges of the slit.
18. 30 mm (1.2 in.)
19. Tapes (Fix the corrugated tubes on the parking brake cables.)
20. View C
21. 70 mm (2.8 in.)
18-16 APPENDIX
Cable, Wire, and Hose Routing
1. Speedometer Cable
2. Clamp the speedometer cable with the parking brake cable.
3. Parking Brake Cable
Cable, Wire, and Hose Routing
This page intentionally left blank.
APPENDIX 18-17
18-18 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 18-19
Cable, Wire, and Hose Routing
1. Run the cables straight to front.
2. Trim
3. Run the cables under the main harness and fuel hose.
4. Run the cables on the damper of right rear brake pipe.
5. Throttle Cable
6. Fix the differential shift cable, 2WD/4WD shift cable and speedometer cable with the clamp.
7. Be sure that there is clearance between the cables and the shaft drive.
8. Fix the transmission shift cable and hi/low shift cable with the band.
9. Clamp
10. Differential Shift Cable: Keep 25 mm (0.98 in.) or more clearance between the rear shock absorber and differential shift cable. Run the cable on the outside of right rear brake hose.
11. 2WD/4WD Shift Cable: Keep 25 mm (0.98 in.) or more clearance between the rear shock absorber and 2WD/4WD shift cable. Run the cable on the outside of right rear brake hose.
12. Transmission Shift Cable
13. Hi/Low Shift Cable
14. Band
15. Speedometer Cable
16. Front
17. Right Side View of Rear Area
18. Set the white mark between center bracket and clamp.
18-20 APPENDIX
Cable, Wire, and Hose Routing
1. Run the speed sensor lead through inside of the 2WD/4WD shift cable and differential shift cable.
2. Band
3. Tail/Brake Light Lead
4. 80 mm (3.15 in.)
5. Clamp
6. Band
7. Neutral Switch Lead
8. Detail A
9. Fill up lithium grease (NLGI Grade No.2).
10. Band
11. Neutral Switch Lead
12. 80 mm (3.15 in.)
13. Tape the tube at both ends.
14. 490
∼ 500 mm (19.3 ∼ 19.7 in.)
15. Front
16. View from Top
17. Upper
18. Right
19. Detail B
20. Detail C
Cable, Wire, and Hose Routing
APPENDIX 18-21
1. Floor Center Panel
2. Trim
3. Run the main harness under the leads.
4. Main Harness
5. Alternator Lead (Brown)
6. Alternator Cable (Red)
7. Starter Motor Lead
8. Battery (–) Cable (to Engine Ground)
9. Battery (+) Cable (to Starter Motor)
10. Align the white tape of the harness with this clamp.
11. Band
12. Parking Brake Switch Lead
13. Starter Circuit Relay
14. Preheating Timer
15. Radiator Fan Relay
16. Glow Plug Relay
17. Run the branch of harness on right side of clamp.
18. Run the battery (+) (–) cables on the rubber damper for the left rear brake line.
19. Front
20. Upper
21. Inside
18-22 APPENDIX
Cable, Wire, and Hose Routing
1. Alternator Lead
2. Main Harness
3. Battery (+) Cable
4. Battery (–) Cable
5. Battery
6. Band
7. Fuse Box 1
8. Fuse Box 2
9. Radiator Fan Breaker
10. Yellow Mark
11. Yellow Tape
Cable, Wire, and Hose Routing
This page intentionally left blank.
APPENDIX 18-23
18-24 APPENDIX
Cable, Wire, and Hose Routing
KAF950G9
∼ GC/HA
Cable, Wire, and Hose Routing
1. Band
2. Fuel Return Hose
3. Fuel Output Hose
4. Fuel Filter
5. Fuel Pipes
6. Fuel Tank
7. Fitting
8. Seal
9. Upper Wall of Fuel Tank
10. Clamp
11. Output or Return Hoses
12. Air Vent Hose
13. Check Valve
14. Joint
15. To Clamp on Center Bar
16. To Hole in Floor Board
17. From Fuel Tank
18. To Injection Pump
19. From Injection Pump
20. To Fuel Tank
21. Harness and Leads
22. Brake Pipe
23. All Cables
24. Position the tabs of clamps facing toward backside of vehicle.
25. Section A-A
26. Pass the fuel hose through clamp.
APPENDIX 18-25
18-26 APPENDIX
Cable, Wire, and Hose Routing
KAF950GD
Cable, Wire, and Hose Routing
1. Band
2. Fuel Return Hose
3. Fuel Output Hose
4. Fuel Filter
5. Fuel Pipes
6. Fuel Tank
7. Fitting
8. Seal
9. Upper Wall of Fuel Tank
10. Clamp
11. Output or Return Hoses
12. Air Vent Hose
13. Check Valve
14. Joint
15. To Clamp on Center Bar
16. To Hole in Floor Board
17. From Fuel Tank
18. To Injection Pump
19. From Injection Pump
20. To Fuel Tank
21. Harness and Leads
22. Brake Pipe
23. All Cables
24. Position the tabs of clamps facing toward backside of vehicle.
25. Section A-A
26. Pass the fuel hose through clamp.
APPENDIX 18-27
18-28 APPENDIX
Cable, Wire, and Hose Routing
KAF950G9
∼ GC/HA
1. Horn Button
2. Horn Switch Contact
3. Run the born switch lead to the straightly down (Do not twist it around the steering shaft).
4. Ground Lead
5. To Main Harness
6. Band
7. Front
8. Installation condition of horn switch contact.
9. View from A
Cable, Wire, and Hose Routing
APPENDIX 18-29
1. Differential Shift Cable
2. Cable Bracket
3. About 100 mm (3.94 in.)
4. Cable Clamp
5. 2WD/4WD Shift Cable
18-30 APPENDIX
Cable, Wire, and Hose Routing
EUR Model
1. Tail/Brake Light Lead
2. Band
3. Neutral Switch
4. Shift Lever
5. Reverse Switch
6. Switch Holder
7. Clearance: 1
∼ 2 mm (0.04 ∼ 0.08 in.)
Adjust the switch location to this clearance in shift lever working condition.
8. Tail/Brake Light
9. Reverse Light
10. Bracket
11. Cargo Bed
12. Cap
13. Bracket
14. View A
15. View B
APPENDIX 18-31
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 rotating:
Neutral switch trouble
Starter motor trouble
Battery voltage low
Relays not contacting or operating
Wiring open or shorted
Main switch trouble
Fuse blown
Starter motor rotating but engine doesn’t turn over:
Starter motor trouble
Pinion or ring gear worn
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Camshaft seizure
No fuel flow:
No fuel in tank
Fuel tank air vent obstructed
Fuel injection pump trouble
Fuel filter clogged
Fuel line clogged
Compression low:
Fuel injection nozzle loose
Glow plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Poor Running at Low Speed:
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Fuel tank air vent obstructed
Fuel injection pump trouble
Compression low:
Fuel injection nozzle loose
Glow plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Other:
Engine oil viscosity too high
Front final gear case oil viscosity too high
Drive train trouble
Brake dragging
Poor Running or No Power at High Speed:
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Fuel tank air vent obstructed
Fuel line clogged
Fuel injection pump trouble
Compression low:
Fuel injection nozzle loose
Glow plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
18-32 APPENDIX
Troubleshooting Guide
Miscellaneous:
Brake dragging
Overheating
Engine oil level too high
Engine oil viscosity too high
Front final gear case oil viscosity too high
Drive train trouble
Overheating:
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Converter and/or belt excessive heating:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
Driven pulley spring broken or weak
Drive pulley spring broken or weak
Idle speed too high
Converter fan damaged
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Front final gear case overheating:
Insufficient oil
Bevel gears maladjusted
LSD clutches maladjustment
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Wrong coolant mixed ratio
Cooling system component incorrect:
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan switch trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged
Over Cooling:
Radiator fan switch trouble
Thermostat trouble
Converter Operation Faulty:
Belt slipping:
Belt dirty, or worn
Drive or driven pulley sheave dirty or worn
Driven pulley spring broken or weak
Converter engagement speed too low:
Drive pulley spring broken or weak
Converter engagement speed too high:
Belt drive or worn
Drive or driven pulley sheave dirty or worn
Drive pulley weight doesn’t move smoothly
Drive pulley movable sheave doesn’t move smoothly
Drive or driven pulley movable sheave bush worn
Drive pulley weight or roller worn
Shifting too quickly:
Drive pulley spring weak
Driven pulley spring weak or incorrectly installed (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 sheave doesn’t move smoothly
Driven pulley spring incorrect installed (too tight)
Driven pulley movable sheave doesn’t move smoothly
Gear Shifting Faulty:
Doesn’t go into gear:
Shift arm bent or seized
Gear stuck on the shaft
Shift cable maladjusted
Shift cable lubrication inadequate
Shift cable damaged
Jumps out of gear:
Shifter groove worn
Gear dogs worn
Shift arm positioning bolt spring weak or broken
Shift block worn
Transmission shaft, and/or gear splines worn
Shift cable maladjusted
Overshifts:
Shift arm positioning bolt spring weak or broken
Shift cable maladjusted
Abnormal Engine Noise:
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Fuel injection nozzle incorrect
Overheating
APPENDIX 18-33
Troubleshooting Guide
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Rocker arm push rod runout excessive
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken, or stuck
Piston seizure or damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mount loose
Crankshaft bearing worn
Cooling fan belt loose
Abnormal Drive Train Noise:
Converter noise:
Belt worn
Drive or driven pulley sheave worn
Drive or driven pulley movable sheave bush worn
Drive or driven pulley mount loose
Driven pulley shoe worn
Drive pulley weight or roller side washer worn
Drive pulley weight or roller worn
Transmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Transmission oil insufficient
Final drive noise:
Bearing worn
Gears worn or chipped
Metal chips jammed in gear teeth
Insufficient lubricant
Bevel gears maladjusted
LSD clutch friction plate worn
LSD clutch spring worn
Universal joint damaged
Abnormal Frame Noise:
Shock absorber noise:
Shock absorber damaged
Brake noise:
Brake linings overworn or worn unevenly
Drum worn unevenly or scored
Brake spring(s) weak or broken
Foreign matter in hub
Brake not properly adjusted
Other noise:
Bracket, nut, bolt, etc.
not properly mounted or tightened
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Brown smoke:
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 assembly damaged
Tire air pressure too low
LSD clutch maladjusted
EPS unit trouble
EPS ECU trouble
Noise when turning:
Damaged side gear or pinion (front final gear case)
Worn clutch friction plate (front final gear case)
Worn clutch spring (front final gear case)
ESP unit mount loose
Steering wheel shakes or excessively vibrates:
Tire(s) worn
Suspension arm bushing worn
Tie-rod joint worn
Wheel rim warped
Axle shaft bearing worn
Steering wheel mount loose
Steering bolt or nut loose
Steering wheel pulls to one side:
Frame bent
Wheel misalignment
Suspension arm bent or twisted
Steering shaft bent
Steering gear assembly damaged
Front or rear tire air pressure unbalanced
Shock absorber unbalanced
18-34 APPENDIX
Troubleshooting Guide
Shock absorption unsatisfactory:
(Too hard)
Tire air pressure too high
Shock absorber damaged
(Too soft)
Tire air pressure too low
Shock absorber oil leaking
Shock absorber spring weak
Brake Doesn’t Hold:
Air in the brake line
Brake fluid leakage
Brake fluid deteriorated
Primary or secondary cup trouble
Master or wheel cylinder scratched inside
Brake not properly adjusted
Linings overworn or worn unevenly
Drum worn unevenly or scored
Oil, grease on lining and drum
Dirt, water between lining and drum
Overheated brakes
Battery Trouble:
Battery discharged:
Battery faulty
Battery cable making poor contact
Load excessive (e.g., bulb of excessive wattage)
Main switch trouble
Alternator trouble
Wiring faulty
Battery overcharged:
Alternator trouble
Battery faulty
Year
2009
2010
2010
2011
2012
2013
MODEL APPLICATION
Model
KAF950G9
KAF950GA
KAF950HA
KAF950GB
KAF950GC
KAF950GD
Beginning Frame No.
JK1AFDG1
□
9B500001
JK1AF950GGB600001
JK1AFDG1
□
AB502001
JK1AF950GGB600601
JK1AFDH1
JK1AFDG1
□
AB500001
□
BB503301
JK1AF950GGB601001
JK1AFDG1
□
CB505101
JK1AF950GGB601401
JK1AFDG1
□
DB508101
JK1AF950GGB601901
□
:This digit in the frame number changes from one machine to another.
Part No.99924-1409-05
Printed in Japan
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Key Features
- Powered by a diesel engine for added power and torque
- Four-wheel drive for added traction in all conditions
- Cargo bed for hauling materials
- Winch for pulling heavy objects
- Roll cage for added safety
- Tilt steering for added comfort
- Independent suspension for a smooth ride
- Hydraulic disc brakes for added stopping power
- Electric power steering for easy maneuverability
- Comfortable seating for two people
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Frequently Answers and Questions
What is the Kawasaki KAF950GDF?
What type of engine does the Kawasaki KAF950GDF have?
Does the Kawasaki KAF950GDF have four-wheel drive?
What are some of the features of the Kawasaki KAF950GDF?
Is the Kawasaki KAF950GDF comfortable to drive?
Is the Kawasaki KAF950GDF safe to drive?
Can the Kawasaki KAF950GDF be used to power accessories?
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