Kawasaki MULE 610 4X4 - DATASHEET 2011 Service manual

MULE 610 4×4

MULE 600

Utility Vehicle

Service Manual

Property of www.SmallEngineDiscount.com - Not for Resale


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.

General Information

Periodic Maintenance

Fuel System

Engine Top End

Converter System

Engine Lubrication System

Engine Removal/Installation

Engine Bottom End

Transmission

Wheels/Tires

Final Drive

Brakes

Suspension

Steering

Frame

Electrical System

Appendix

9 j

10 j

11 j

12 j

13 j

14 j

15 j

16 j

17 j

1 j

2 j

3 j

4 j

5 j

6 j

7 j

8 j



MULE 610 4×4

MULE 600

Utility Vehicle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery

Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.


© 2004 Kawasaki Heavy Industries. Ltd., First Edition (1) : Oct. 10, 2004 (M)

g h

°F ft

L

A

ABDC

AC

ATDC

BBDC

BDC

BTDC

°C

DC

F

LIST OF ABBREVIATIONS

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) lb m min

N

Pa

PS psi r rpm

TDC

TIR

V

W

Ω 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)

Read OWNER’S MANUAL before operating.


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. Then, it is led to the intake 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 carburetor and ignition system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere.

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

(United States Model only)

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any way which results in an increase in noise level.


Foreword

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 Special Tool

Catalog or 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.

Guide shows you all of the product’s system and assists in locating their chapters.

Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the

Table of Contents on the first page of the chapter to find the Ignition Coil section.

Whenever you see these WARNING and

CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) 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

How to Use This Manual

instructions indicating which parts require spec-

In this manual, the product is divided into ified tightening torque, oil, grease or a locking its major systems and these systems make up agent during assembly.

the manual’s chapters. The Quick Reference



GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1-2

1-7

1-8

1-9

1-12

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 wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive

(+) terminal of the battery then the negative (–) wire to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.



Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.


Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

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 or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service

Manual, follow the procedures given.




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.

Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive 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 new gaskets and replace used

O-rings when re-assembling.

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a

Non-Permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.



Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.


Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

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 circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.




Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.


Model Identification

KAF400-A1 Left Side View


KAF400-A1 Right Side View

The KAF400-C1 is identical to the KAF400-A1 in every aspect: controls, features, and specifications except the camouflage surface treatment and weight.



Model Identification

KAF400-B1 Left Side View

KAF400-B1 Right Side View


General Specifications

Items

Dimensions

Overall Length

Overall Width

Overall Height

Wheelbase

Tread:

Front

Rear

Ground Clearance

Seat Height

Dry Weight

Curb Weight:

Front

Rear

Fuel Tank Capacity

Cargo Bed (L × W × H)

Performance

Minimum Turning Radius

Engine

Type

Cooling System

Bore and Stroke

Displacement

Compression Ratio

Carburetion System

Starting System

Ignition System

Ignition Timing

Spark Plug

Valve Timing

Inlet:

Open

Close

Duration

Exhaust:

Open

Close

Duration

Lubrication System

Engine Oil:

Type

Viscosity


KAF400-A1/B1/C1

2 720 mm (107.09 in.)

1 335 mm (52.56 in.)

(A, C) 1 802 mm (70.94 in.), (B) 1 781 mm (70.12 in.)

1 779 mm (70.04 in.)

1 051 mm (41.38 in.)

999 mm (39.33 in.)

(A, C) 170 mm (6.69 in.), (B) 155 mm (6.10 in.)

(A, C) 780 mm (30.71 in.), (B) 768 mm (30.24 in.)

(A) 442 kg (975 lb), (B) 413 kg (911 lb), (C) 448 kg (988 lb)

(A, C) 199 kg (439 lb), (B) 179 kg (395 lb)

(A) 259 kg (571 lb), (B) 250 kg (551 lb), (C) 265 kg (584 lb)

15.5 L (4.1 US gal)

1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.)

3.3 m (10.83 ft)

4-stroke, OHV, 2-valves, 1-cylinder

Positive air-cooled

82 × 76 mm (3.23 × 2.99 in.)

401 mL (24.47 cu in.)

8.6

Carburetor, NIKKI 6C1026

Electric starter

Magneto and Transistor

20° Constant

NGK BPR5ES

19° BTDC

61° ABDC

260°

58° BBDC

22° ATDC

260°

Forced lubrication (wet sump)

API SF or SG

API SH or SJ with JASO MA class

SAE10W-40

1.4 L (1.5 US qt)



Items

Drive Train

Primary Reduction System:

Type

Reduction ratio

Transmission Gear Ratio:

Forward:

High

Low

Reverse:

Low

Final Drive System:

Type

Reduction Ratio

Front

Rear

Overall Drive Ratio:

Forward:

High

Low

Reverse:

Low

Front Final Gear Case Oil (A, C):

Type

Capacity

Transmission Oil (A, C):

Type

KAF400-A1/B1/C1

Belt drive torque converter

3.653

∼

0.794

2.916 (35/24 × 36/18)

(A, C) 4.315 (41/19 × 36/18), (B) –

3.750 (30/16 × 36/18)

(A, C) Gear (4WD/2WD), (B) Gear (2WD)

3.851 (16/18 × 39/9)

4.000 (64/16)

9.263

(A, C) 13.706, (B) –

11.910

API GL-5 SAE140 or GL-6 SAE90 Hypoid gear oil for LSD

0.2 L (0.2 US qt)

API GL-5 Hypoid gear oil, SAE90 (above 5°C, 41°F) or

SAE80 (below 5°C, 41°F)

(A, C) 2.4 L (2.5 US qt), (B) 2.2 L (2.3 US qt) Capacity

Frame

Type

Caster (Rake Angle)

Camber

Trail

Tire:

Front

Rear

Steering Type

Suspension:

Front:

Type

Wheel travel

Rear:

Type

Steel tube, Ladder

8°

1°

(A, C) 40 mm (1.57 in.), (B) 33 mm (1.30 in.)

(A, C) 24 × 9.00-10, Tubeless, (B) 22 × 9.00-10, Tubeless

(A, C) 24 × 11.00-10, Tubeless, (B) 22 × 11.00-10, Tubeless

Rack and pinion

MacPherson strut

78 mm (3.07 in.)

Unit Swing

78.7 mm (3.10 in.)



Items

Brake Type:

Front and Rear

Parking brake type

Electrical Equipment

Battery

Drum (Hydraulic)

KAF400-A1/B1/C1

Drum (Mechanical internal expansion)

12 V 14 Ah

Headlight:

Type

Bulb

Tail/Brake Light

Reverse Light (EUR)

Alternator:

Type

Semi-sealed beam

12 V 35 W × 2

12 V 5/21 W

12 V 10 W

Rated output

Load Capacity

Single-phase AC

17 A, 12.5 V

Maximum Vehicle Load

(Including Occupants and Cargo) 420 kg (926 lb)

Maximum Cargo Bed Load 181 kg (400 lb)

Specifications are subject to change without notice, and may not apply to every country.

A: KAF400A, MULE 610 4 × 4

B: KAF400B, MULE 600

C: KAF400C, MULE 610 4 × 4 (Camouflage-Surface-Treated Model)

EUR: Europe Model



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 mL mL mL

L

L

L

L

×

×

×

×

×

×

×

×

0.2200

=

1.057

=

0.8799

=

2.113

=

1.816

=

0.03381

=

0.02816

=

0.06102

= gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

Units of Force

N × 0.1020

=

N kg kg

×

×

×

0.2248

=

9.807

=

2.205

= kg lb

N lb

Units of Length

km × 0.6214

= m mm

×

×

3.281

=

0.03937

= mile ft in

Units of Torque

N·m × 0.1020

=

N·m

N·m kgf·m kgf·m kgf·m

×

×

×

×

×

0.7376

=

8.851

=

9.807

=

7.233

86.80

=

= kgf·m ft·lb in·lb

N·m ft·lb in·lb

Units of Pressure

kPa × 0.01020

= kPa kPa kgf/cm² × kgf/cm² × cm Hg ×

×

×

0.1450

=

0.7501

=

98.07

14.22

1.333

=

=

= kgf/cm² psi cmHg kPa psi kPa

Units of Speed

km/h × 0.6214

= mph

Units of Power

kW kW

PS

PS

×

×

×

×

1.360

=

1.341

=

0.7355

=

0.9863

=

PS

HP kW

HP

Units of Temperature:


PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Periodic Maintenance Chart ..............

Torque and Locking Agent.................

Specifications ....................................

Special Tools .....................................

Periodic Maintenance Procedures.....

Fuel System....................................

Throttle Pedal Free Play

Inspection..................................


Adjustment ................................

Idle Speed Inspection ..................

Idle Speed Adjustment.................

Air Cleaner Element Cleaning......

Fuel Hoses And Connections

Inspection..................................

Fuel Hoses Replacement.............

Fuel Filter Replacement...............

Fuel System Cleanliness

Inspection..................................

Engine Top End ..............................

Valve Clearance Inspection .........

Valve Clearance Adjustment........

Spark Arrester Cleaning...............

Converter System ...........................

Drive Belt Inspection ....................

Drive Belt Deflection Inspection ...

Drive Belt Deflection Adjustment .

Converter Driven Pulley Shoe

Inspection..................................

Converter Air Cleaner Element

Cleaning/Inspection...................

Converter Dust or Water Drain ....

Engine Lubrication System .............

Engine Oil Change.......................

Oil Filter Replacement .................

Transmission ..................................

Transmission Oil Change.............


2-14

2-15

2-15

2-16

2-16

2-16

2-17

2-17

2-18

2-18

2-18

2-19

2-19

2-20

2-21

2-21

2-21

2-22

2-22

2-22

2-2

2-4

2-9

2-11

2-12

2-12

2-12

2-12

2-12

2-13

2-13

Wheels/Tires ...................................

Wheels Nuts Tightness

Inspection..................................

Tire Wear Inspection ....................

Final Drive (KAF400-A/C models) ..

Front Final Gear Case Oil

Change......................................

Brakes.............................................

Brake Fluid Level Inspection........

Brake Fluid Change .....................

Brake Pedal Play Inspection ........

Brake Master Cylinder Cup and

Dust Seal Replacement ............

Brake Hose and Pipe Inspection..

Brake Hose and Pipe

Replacement .............................

Brake Wear Inspection.................

Brake Wheel Cylinder Assembly

Replacement .............................

Parking Brake Lever Inspection ...

Steering ..........................................

Steering Inspection ......................

Steering Joint Dust Boot

Inspection..................................

Frame .............................................

Seat Belt Inspection .....................

Electrical System ............................

Spark Plug Cleaning/Inspection...

Spark Plug Gap Inspection ..........

Electrolyte Level Inspection .........

Electrolyte Specific Gravity

Inspection..................................

Brake Light Switch Inspection......

General Lubrication ........................

Bolts, Nuts, and Fasteners .............

Tightness Inspection ....................

2-23

2-23

2-23

2-23

2-23

2-24

2-24

2-25

2-26

2-27

2-28

2-28

2-29

2-30

2-31

2-32

2-32

2-32

2-33

2-33

2-33

2-33

2-33

2-33

2-34

2-34

2-35

2-36

2-36

2


2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY

Whichever comes first

First

Service

Regular Service

After 50 h, or 1 000 km of use

Every

250 h, or

5 000 km of use

Every

500 h, or

10 000 km of use

See

Page

OPERATION

Every

ENGINE

Converter drive belt - inspect*

Converter driven pulley shoe - inspect*

Converter dust or water - clean*

•

2-18

•

2-19

•

2-21

2-20

Converter air cleaner element - clean*

Air cleaner element - clean*

Valve clearance - inspect

Engine oil - change*

Oil filter - replace*

Throttle pedal play - inspect

Idle speed - adjust

1 year

•

•

•

•

•

•

•

•

•

•

•

2-13

•

2-16

2-21

2-22

•

2-12

2-12

Fuel hose - replace

Fuel filter - replace*

Fuel system cleanliness - inspect

4 years 2-15

•

2-15

•

2-16

2-14 Fuel hoses and connections -inspect*

Spark plug - clean and gap

Spark arrester - clean

•

•

•

•

•

2-33

2-17

CHASSIS

Steering - inspect

Steering joint dust boots - inspect

Brake pedal play - inspect*

Parking brake lever - inspect

Brake hose and pipe - inspect

Brake fluid level - inspect

Brake wear - inspect*

Tire wear - inspect*

Battery - inspect

Brake light switch - inspect

Seat belt - inspect

General lubrication - perform*

Bolts, nuts, and fasteners tightness - inspect

Wheel nuts tightness - inspect

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

2-32

2-32

2-26

2-31

2-28

2-24

2-29

2-23

2-33

2-34

2-33

2-35

2-36

2-23



Periodic Maintenance Chart

FREQUENCY

Whichever comes first

First

Service

Regular Service

After 50 h, or 1 000 km of use

Every

250 h, or

5 000 km of use

Every

500 h, or

10 000 km of use

See

Page

OPERATION

Front final gear case oil and transmission oil

- change*

Brake fluid - change

Brake master cylinder cup and dust seal replace

Brake wheel cylinder assembly -replace

Every

1 year

2 years

2 years

• •

2 years

Brake hose - replace 4 years

•

: Clean, adjust, lubricate, torque, or replace parts as necessary.

*: Service more frequently when operated in mud, dust, or other harsh riding conditions.

2-22

2-23

2-25

2-27

2-30

2-28



Torque and Locking Agent

The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket.

L: Apply a non-permanent locking agent to the threads.

MO: Apply molybdenum disulfide oil (the weight ratio of the mixture between engine oil and disulfide grease is 10 : 1).

O: Apply an oil to the threads, seated surface, or washer.

R: Replacement Parts

S: Tighten the fasteners following the specified sequence.

SS: Apply a silicone sealant to the threads.

Fastener

N·m

Torque kgf·m ft·lb

Remarks

Fuel System

Air Cleaner Housing Bolts

Carburetor Mounting Nuts

Choke Valve Screws

Throttle Valve Screws

Pilot Jet

Pilot Jet Plug

Main Jet

Drain Screw

Float Chamber Bolt

Panel Cover Bolts

Control Panel Bolt

Plate Connection Bolts

Control Panel Mounting Bolts

Governor Arm Nut

Fuel Pump Mounting Bolts

Air Cleaner Housing Bolts

Fuel Pump Bracket Bolt

Breather Mounting Bolt

Brearher Bracket Bolt

Engine Top End

Cylinder Head Cover Bolts

Cylinder Head Bolts

Engine Shroud Bolts

Valve Adjusting Nut Lock Screw

Rocker Arm Bolts

Exhaust Pipe Clamp Nuts

Muffler Clamp Nuts

Muffler Mounting Bolts


Drive Pulley Bolt

Drive Pulley Cover Bolts

12

52 in·lb

7.8 in·lb

7.8 in·lb

6.1 in·lb

22 in·lb

17 in·lb

17 in·lb

87 in·lb

39 in·lb

61 in·lb

78 in·lb

14

52 in·lb

48 in·lb

12

48 in·lb

78 in·lb

11

1.0

0.45

0.70

0.90

2.0

0.60

0.55

1.7

0.55

0.90

1.5

1.7

0.60

0.09

0.09

0.07

0.25

0.20

0.20

20

5.9

5.4

17

9.8

4.4

6.9

8.8

5.4

8.8

15

17

5.9

0.90

0.90

0.70

2.5

2.0

2.0

6.9

37

5.9

6.9

28

20

31

31

94

23

0.70

3.8

0.60

0.70

2.9

2.0

3.2

3.2

9.6

2.3

61 in·lb

27

52 in·lb

61 in·lb

21

14

23

23

69

17

L

L

S

R

Spider 275 28 203

Weight Pin Nuts 7.0

0.70

61 in·lb



Fastener

Driven Pulley Bolt

Deflection Bolts

Driven Shoe Screws

Converter Cover Bolts

Converter Case Front Bolts (26.5 mm)

Converter Case Rear Bolts (25 mm)

Converter Case Cover Screws

Bracket Bolts

Air Filter Housing Bolts


Oil Line Plugs

Oil Filter

Oil Filter Joint

Joint (KAF400-A/C)

Oil Temperature Sensor (KAF400-A/C)

Engine Oil Drain Plugs

Oil Plug


Engine Mounting Bolts and Nuts

Connecting Plate Bolts (M8)



Connecting Rod Bolts

Breather Valve Screw

Oil Filter Joint

Oil Line Plugs

Crankcase Cover Bolts

Engine Oil Drain Plugs

Transmission

Transmission Cable Holder Bolts



Transmission Case Bolts

Speed Sensor Cap Bolt

Transmission Oil Drain Plug

Cover Screws

Oil Line Plug

Shift Shaft Lever Bolt

Differential Shift Cable Holder Bolts

Plug Bolt (except Europe Model)

Shift Shaft Stop Bolt

Differential Shift Shaft Nut


2.5

2.9

5.6

0.60

0.35

0.70

0.40

2.2

0.70

1.4

0.90

1.5

0.90

2.0

1.5

4.2

2.9

5.6

0.90

0.90

1.5

0.40

1.0

0.40

1.0

0.70

0.75

0.56

0.70

0.70

Torque kgf·m

9.6

0.92

0.11

0.45

2.0

2.0

0.5

0.90

2.0

ft·lb

69

80 in·lb

9.7 in·lb

39 in·lb

14

14

44 in·lb

78 in·lb

14

Remarks

L

34 in·lb

87 in·lb

61 in·lb

65 in·lb

49 in·lb

61 in·lb

61 in·lb

L

L

L

O

L

S

L

L

L

18

21

41

52 in·lb

30 in·lb

61 in·lb

34 in·lb

16

61 in·lb

31

21

41

78 in·lb

78 in·lb

11

35 in·lb

87 in·lb

10

78 in·lb

11

78 in·lb

14

11

24.5

28

55

5.9

3.4

6.9

3.9

21.6

6.9

13.5

8.8

15

8.8

20

15

41.5

28

55

8.8

8.8

15

4.0

9.8

N·m

94

9.0

1.1

4.4

20

20

5.0

8.8

20

3.9

9.8

6.9

7.4

5.5

6.9

6.9



Fastener

Reverse Switch (Europe Model)

Positioning Bolt

Differential Gear Housing Bolts

Wheels/Tires

Wheel Nuts

Final Drive

Oil Filler Cap

Front Final Gear Case Oil Drain Plug

Pinion Gear Nut

Pinion Gear Bearing Holder

Differential Case Bolts

Ring Gear Cover Bolts M8

Ring Gear Cover Bolts M10

Rear Axle Bracket Bolts

Rear Axle Bracket Flange Bolts

Bevel Gear Case Bolts

Yoke Stop Bolt

Driven Bevel Gear Slotted Nut

Bearing Screw

Drive Bevel Gear Nut

2WD/4WD Shift Shaft Nut

2WD/4WD Shift Cable Holder Bolts

Bearing Housing Bolts

Brakes

Push Rod Locknut

Master Cylinder Reservoir Cap

Reservoir Clamp Bolt

Master Cylinder Mounting Bolts

Piston Stop Bolt

Brake Pipe Nipples

Brake Hose Banjo Bolts

Parking Lever Mounting Bolts

Bleed Valves

Wheel Cylinder Mounting Bolts

Breather Fitting

Front Brake Panel Mounting Bolts

Front Axle Nuts

Brake Pipe Nipples

Brake Pipe Mounting Bolt

Bleed Valves


Breather Fitting

1.8

0.35

0.63

2.3

0.90

1.8

2.5

2.3

0.82

1.2

0.61

3.5

15

1.8

2.3

0.82

1.2

0.61

3.5

5.0

2.6

4.8

2.5

5.0

3.0

2.0

16

10

2.0

0.90

12

14

14

2.0

0.90

4.2

Torque kgf·m

1.5

2.5

5.8

3.5

ft·lb

11

18

42

25

13

30 in·lb

55 in·lb

17

78 in·lb

13

18

17

71 in·lb

106 in·lb

53 in·lb

25

108

13

17

71 in·lb

106 in·lb

53 in·lb

25

36

19

35

18

36

22

14

115

72

14

78 in·lb

87

101

101

14

78 in·lb

31

Remarks

L

L

L

MO

L

MO

L

L

L

18

3.4

6.2

22.5

8.8

18

25

22.5

8.0

12

6.0

34

147

18

22.5

8.0

12

6.0

34

29

20

156

98

49

25

47

24.5

49

20

8.8

118

137

137

20

8.8

41.5

N·m

15

25

57

34


Fastener

Rear Axle Nuts

Suspension

Strut Mounting Nuts

Strut Clamp Nuts

Suspension Arm Pivot Bolts

Front Suspension Arm Joint Nuts

Swingarm Joint Nut

Swingarm Rod Bolts

Rear Shock Absorber Mounting Nuts

Steering

Steering Wheel Mounting Nut

Main Shaft Mounting Bolts

Intermediate Shaft Clamp Bolts

Steering Gear Assembly Bracket Bolts

Rack Guide Spring Cap Locknut

Tie-rod Locknuts

Strut Clamp Nuts

Tie-rod End Nuts

Frame

Front Bar Mounting Bolts (Lower)

Front Bar Mounting Bolts (Upper)

Rear Bar Mounting Bolts (L=20 mm)

Rear Bar Mounting Bolts (L=16 mm)

Seat Belt Mounting Bolts


Alternator Cover Bolts

Alternator Rotor Bolt

Ignition Coil Bolts

Spark Plug Wire

Stator Coil Screws

Wire Lead Clamp Bolt

Starter Motor Mounting Bolts

Controller Mounting Bolt (KAF400-A/C)

Regulator/Rectifier Bolts

Joint (KAF400-A/C)

Oil Temperature Sensor (KAF400-A/C)

Neutral Switch


98

44

44

44

34

39

44

98

34

54

34

25

54

3.4

6.9

17

5.4

5.9

56

5.9

22

7.8

7.4

5.5

15

N·m

304

44

98

88.2

78.5

54

50

54

10

4.5

4.5

4.5

3.5

4.0

4.5

10

3.5

5.5

3.5

2.5

5.5

0.60

5.7

0.60

2.2

0.35

0.70

1.7

0.55

0.80

0.75

0.56

1.5

Torque kgf·m

31

4.5

10

9.0

8.0

5.5

5.1

5.5

52 in·lb

41

52 in·lb

16

30 in·lb

61 in·lb

12

48 in·lb

69 in·lb

65 in·lb

49 in·lb

11

ft·lb

224

40

37

40

32

72

65

58

72

32

32

32

25

29

32

72

25

40

25

18

40

Remarks




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 dia.

Mark of Bolt Head

(mm)

6

6

6

8

8

10

10

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

Torque 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

Basic Torque for General Fasteners of Frame Parts

Threads dia.

Torque

(mm)

5

6

8

10

12

N·m

3.4

∼

4.9

5.8

∼

7.9

14

∼

19

26

∼

34

44

∼

61 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



Specifications

Item Standard

Fuel System


Idle Speed

Engine Top End

Valve Clearance (when cold) 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)


2

∼

5 mm (0.08

∼

0.20 in.)

1 100

∼

1 250 r/min (rpm)

Belt Width

Belt Deflection

26.1

∼

27.3 mm (1.03

∼

1.07 in.)

22

∼

32 mm (0.87

∼

1.26 in.)

Service Limit

– – –

– – –

– – –

25.2 mm (0.99 in.)

22

∼

50 mm (0.87

∼

1.97 in.)

1.9 mm (0.75 in.) Wear Shoe Width


Engine Oil:

Type

– – –

Viscosity

Capacity

API SF or SG

API SH or SJ with JASO MA

SAE10W-40

0.85 L (0.9 US qt) (when filter is not removed)

1.4 L (1.5 US qt) (when filter is removed)

Between H and L marks on dipstick

– – –

– – –

– – –

Oil Level

Transmission

Transmission Oil:

Type

Viscosity

Capacity

Oil Level

Wheels/Tires

Tire Tread Depth

Standard Tire:

Front

API "GL-5" Hypoid gear oil

SAE90: above 5°C (41°F) or

SAE80: below 5°C (41°F)

2.4 L (2.5 US qt), (B) 2.2 L (2.3 US qt)

Between H and L level lines

– – –

– – –

– – –

– – –

– – –

– – –

3 mm (0.12 in.)

Rear

(A, C) 24 × 9.00 × 10

DUNLOP KT869M, Tubeless

(B) 22 × 9.00 × 10

DUNLOP KT901, Tubeless

(A, C) 24 × 11.00 × 10


(B) 22 × 11.00 × 10


– – –

– – –

– – –

– – –

Final Drive (A, C)

Front Final Gear Case Oil:

Type

Viscosity

Capacity

API "GL-5 or GL-6" hypoid gear oil for LSD

(Limited Slip Differential gears)

SAE90 (GL-6) or SAE140 (GL-5)

0.2 L (0.2 US qt)

– – –

– – –

– – –

Oil Level Filler opening level – – –



Specifications

Brakes

Brake Fluid:

Type

Item Standard

DOT3

Fluid Level

Brake Pedal Play

Between upper and lower level lines

2

∼

5 mm (0.08

∼

0.20 in.)

Brake Drum Inside Diameter 165.00

∼

165.16 mm

(6.4961

∼

6.5023 in.)

Brake Shoe Lining Thickness 4 mm (0.16 in.)

Parking Brake Lever Travel 8

∼

12 notches (clicks)

Steering

Steering Wheel Free Play


Spark Plug Gap

Battery:

Capacity

Electrolyte Level

Specific Gravity

0

∼

0.7

20 mm (0

∼

∼

0.79 in.)

0.8 mm (0.028

∼

0.032 in.)

12 V 14 Ah

Between upper and lower level (see text)

1.270 @ 20° (68°F)

Switches:

Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel

A: KAF400-A Model

B: KAF400-B Model

C: KAF400-C Model

Service Limit

– – –

– – –

– – –

165.75 mm (6.526 in.)

1 mm (0.04 in.)

– – –

– – –

– – –

– – –

– – –

– – –

– – –


Special Tools

Inside Circlip Pliers:

57001-143


Oil Filter Wrench:

57001-1249



Periodic Maintenance Procedures

Fuel System

Throttle Pedal Free Play Inspection

•

Check that the throttle pedal moves smoothly from full open to close.

If the throttle pedal does not return properly, lubricate the throttle cable and link (see Fuel System chapter).

•

Check the throttle pedal free play [A].

Throttle Pedal Free Play

Standard: 2

∼

5 mm (0.08

∼

0.20 in.)

If the free play is incorrect, adjust the throttle cable.

Throttle Pedal Free Play Adjustment

•

Tilt up the cargo bed.

•

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

•

Slide the adjuster [B] until the proper amount of throttle pedal free play is obtained.

•

Tighten the mounting nuts securely.

•

Start the engine.

•

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 a damaged cable could result in an unsafe operating condition.

NOTE

○

If the throttle pedal free play cannot be adjusted by using the adjuster at the cable lower end, use the cable adjuster [A] at the cable upper end. Do not forget to securely tighten the adjuster mounting nuts [B].

Idle Speed Inspection

•

Start the engine and warm it up thoroughly.

•


•

Check the idle speed with a suitable tachometer.

Idle Speed

Standard: 1 100

∼

1 250 r/min (rpm)

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



Idle Speed Adjustment

•

Start the engine and warm it up thoroughly.

•


•

Remove:

Guard Plate (see Frame chapter)

Link Plate Cover [A]

•

Loosen the accel lever stopper screw [B] on the control panel and idle adjusting screw [C] on the link bracket.


•

Turn the idle adjusting screw [A] at the carburetor until the idle speed is correct.

Idle Speed

Standard: 1 100

∼

1 250 r/min (rpm)

•

After the adjustment, screw in the idle adjusting screw [A] on the link bracket until the screw lightly touches the link lever [B].

•

Finally screw in the accel lever stopper screw [C] until it keeps clearance by 1 mm (0.04 in.) to accel lever [D].

•

Depress and release the throttle pedal a few times to make sure that the idle speed does not change. Readjust if necessary.

Air Cleaner Element Cleaning

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

Clean the element in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area.

Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.




•

Remove:

Air Cleaner Element (see Air Cleaner Element Removal)

Foam Element [A]

Paper Element [B]

•

Clean the foam element in a bath of high flash-point solvent using a soft bristle brush.

•

Squeeze it dry in a clean towel.

CAUTION

Do not wring the element or blow it dry; the element can be damaged.

•

Inspect the foam element for damage.

If it is torn, punctured, or hardened, replace it.

NOTE

○

Replace the foam element after cleaning it five times or if it is damaged.

•

Clean the paper element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed air from the inside to the outside (from the clean side to the dirty side).

•

Inspect the element material for damage.

If any part of the element is damaged, the element must be replaced.

Fuel Hoses And Connections Inspection

•

Lift up the cargo bed and seat.

•

Check the fuel hoses and fittings for deterioration, cracks and signs of leakage.

Replace the fuel hose if any fraying, leak [A], cracks [B] or bulges [C] are noticed.

•

Check that the hoses are securely connected and clamps are installed correctly.

•

When installing, route the hoses according to Cable,

Wire, and Hose Routing section in the Appendix chapter.

•

When installing the 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.

•

Slide out the clamps [A].

•

Remove the hoses [B] (see Exploded View in Fuel System chapter).

•

When installing, route the hoses according to Cable,

Wire, and Hose Routing section in the Appendix chapter.

•

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.


•

Fit the fuel hose [A] onto the fitting fully and install the plate clamp [B] beyond the raised rib [C].

1

∼

2 mm (0.0039

∼

0.0078 in.) [D]

○

The hose end must reach the filler [E] or be as near as possible to the step [F].

Fuel Filter Replacement

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

•

Tilt up the seat.

•

Open the rubber damper [A].

•

Remove:

Clamps [B] and Fuel Hoses

Fuel Filter [C]




•

Install the fuel filter [A] so that the arrow [B] on it shows the fuel flow from the fuel tank to the fuel pump.

•

Install the clamps securely.

Fuel System Cleanliness Inspection

WARNING


•

Remove:

Cargo Bed (tilt up)

•

Place a suitable container under the carburetor.

•

Turn out the drain screw [A] a few turns to drain some fuel from the carburetor, and check for water or dirt in the fuel.

If any water or dirt comes out, clean the carburetor and fuel tank (see Fuel Tank) and check the fuel filter.

•

Tighten the drain screw securely.

Engine Top End

Valve Clearance Inspection

NOTE

○

Valve clearance must be checked when the engine is cold (at room temperature).

•

Remove:

Guard Plates (see Frame chapter)

Cooling Fan Cover (see Alternator Rotor and Stator Removal section in the Electrical System chapter)

Oil Level Gauge [A]

Cylinder Head Cover Bolts [B]

Cylinder Head Cover [C]

Spark Plugs



•

Position the crankshaft at TDC of the end of the compression stroke.

•

Turn the alternator rotor counterclockwise so that the projection [A] on the plate [B] comes to the cylinder as shown.

○

Remove the spark plug, if the thin rod is inserted in the plug hole, and the rotor is rotated, a top position of the piston is understood.

•

Check both rocker arms are free. If not, turn the rotor more one turn and free both rocker arms.


•

Using a thickness gauge [A], measure the valve clearance between the rocker arm and the valve stem.

If the valve clearance is incorrect, adjust it.

Valve Clearance (when cold)

Standard: 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

Valve Clearance Adjustment

•

Loosen the valve adjusting nut lock screw [A].

•

Turn the valve adjusting nut [B] until the correct clearance is obtained.

•

Holding the adjusting nut, tighten the lock screw.

Torque - Valve Adjusting Nut Lock Screw: 6.9 N·m (0.70

kgf·m, 61 in·lb)

Spark Arrester Cleaning

WARNING

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

•

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

•

Apply the parking brake.

•

In an open area away from combustible materials, start the engine with the gear shift lever in the N (neutral) position.

•

Raise and lower engine speed while tapping on the muffler with a rubber mallet until the carbon particles are purged from the muffler.

WARNING

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

•

Stop the engine.

•

Install the drain plug.





Drive Belt Inspection

•

Remove the driver belt (see Converter System chapter).

•

Measure the width [A] of the belt at several locations with a pair of suitable straightedges [B] as shown.

If any measurements exceed the service limit, replace the belt.

Belt Width

Standard: 26.1

∼

27.3 mm (1.03

∼

1.07 in.)

Service Limit: 25.2 mm (0.99 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.

Drive Belt Deflection Inspection

•

Remove the torque converter cover (see 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 [A] at the three locations by rotating the pulley as shown:

○

Place a straightedge [B] on top of the belt between the drive pulley [C] and the driven pulley [D].

○

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: 22

∼

32 mm (0.87

∼

1.26 in.)

Service Limit: 22

∼

50 mm (0.87

∼

1.97 in.)

If the belt deflection of all of the three locations is within the specified range, the deflection is normal.

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 shims under the deflection bolts.

•

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.

Even if the deflection is adjusted, when the belt deflection is greater than the service limit, replace the drive belt.



Drive Belt Deflection Adjustment

•

Inspect the drive belt deflection (see Drive Belt Deflection

Inspection).

If the belt deflection is more than 50 mm (1.97 in.), remove the deflection bolts [A] and shims [B] to decrease it.

○

The rule-of-thumb is: 0.1 mm (0.004 in.) change in shim thickness equals about 1.4 mm (0.055 in.) change in belt deflection.

If the belt deflection is less than 22 mm (0.87 in.), add the shims to increase it.

○

The rule-of-thumb is: 0.1 mm (0.004 in.) change in shim thickness equals about 1.6 mm (0.063 in.) change in belt deflection.

shims

Part No.

92180-0150

92180-0151

92180-0152

92180-0153

92180-0154

92180-0155

92180-0156

92180-0157

Thickness

0.8 mm (0.032 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

1.4 mm (0.055 in.)

1.6 mm (0.063 in.)

1.8 mm (0.071 in.)

2.0 mm (0.079 in.)

2.3 mm (0.091 in.)

92180-0158

92180-0159

2.6 mm (0.102 in.)

2.9 mm (0.114 in.)

92180-0160

3.2 mm (0.126 in.)

•

Tighten:

Torque - Deflection Bolts: 9.0 N·m (0.92 kgf·m, 80 in·lb)

•

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.

Converter Driven Pulley Shoe Inspection

•

Remove the driven pulley (see Converter System chapter).

•

Disassemble the driven pulley (see Converter System chapter).

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





•

Measure the width [A] between the upper surface [B] of the movable sheave [C] and the bottom edge [D] of worn area of the shoe [E].

If the width is greater than the service limit, replace the shoe.

Wear Shoe Width


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

Clean the element in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area.

Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean element.

•

Remove the air cleaner element (see 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 squeeze it dry in a clean towel. Do not wring the element or blow it dry; the element can be damaged.

•

Inspect the foam element for damage. If it is torn, punctured, or hardened, replace it.

NOTE

○

Replace the foam element after cleaning it five times or if it is damaged.

•

Clean the paper element by tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed air from the inside to the outside (from the clean side to the dirty side).

•

Inspect the element material for damage. If any part of the element is damaged, the element must be replaced.



Converter Dust or Water Drain

•

Remove the drain plug [A] on the bottom of the converter cover to expel dust and/or water accumulated inside.

•

After the draining, insert the drain plug until the flange of the plug contacts on the face [B] of the cover.

○

Do not apply grease to oval line part [C] of the plug, when installing it. However, the soapy water is permitted.



Engine Oil 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 Replacement).

•

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 Plug: 6.9 N·m (0.70 kgf·m, 61 in·lb)

•

Slowly and evenly fill the engine with a good quality oil as specified in the table.

Engine Oil

Type:

Viscosity:

Capacity:

Oil Level:

API SF or SG

API SH or SJ with JASO MA

SAE10W-40

0.85 L (0.9 US qt ) (when filter is not removed)

1.4 L (1.5 US qt ) (when filter is removed)

Between H 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.

Thoroughly warm up the engine, and check for oil leakage


Lubrication System chapter).



Oil Filter Replacement

•

Drain the engine oil.

•

Remove the oil filter [A] with the oil filter wrench [B].

Special Tool - Oil Filter Wrench: 57001-1249

○

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.

•

Replace the filter with a new one.

•

When installing the oil filter, be careful of the following.

○

Apply oil to the gasket [A] before installation.

○

Tighten the filter with the filter wrench.

Special Tool - Oil Filter Wrench: 57001-1249

Torque - Oil Filter: 9.8 N·m (1.0 kgf·m, 87 in·lb)

○

Pour in the specified type and amount of oil.

•

Thoroughly warm up the engine, and check for oil leakage and the oil level (see Oil Level Inspection in the Engine

Lubrication System chapter).

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.

Transmission Oil

Type: API "GL-5" Hypoid gear oil

Viscosity: SAE90: above 5°C (41°F) or

SAE80: below 5°C (41°F)

Capacity: KAF400A/C: 2.4 L (2.5 US qt)

KAF400B: 2.2 L (2.3 US qt)

Oil Level:

Between H and L lines on dipstick

•

Check the oil level (see Transmission Oil Level Inspection in the Transmission chapter).



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: 34 N·m (3.5 kgf·m, 25 ft·lb)

○

Tighten the wheel nuts [1]

∼

[4] in a criss-cross pattern.


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

Service Limit 3 mm (0.12 in.)

Standard Tire

KAF400-A/C

Front:

Rear:

KAF400-B

Front:

Rear:

24 × 9.00-10 DUNLOP KT869M Tubeless

24 × 11.00-10 DUNLOP KT869 Tubeless



Final Drive (KAF400-A/C models)

Front Final Gear Case Oil Change

•

Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle.

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

•

Remove:

Front Guard (see Frame chapter)

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

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




•

After the oil has completely drained out, install the drain plug with a new aluminum gasket, and tighten it.

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

•

Fill the gear case up to the bottom [A] of filler opening [B] with the oil specified below.

Front Final Gear Case Oil

Type:

API "GL-5 or GL-6" hypoid gear oil for

LSD (Limited Slip Differential gears)

Viscosity:

Capacity:

SAE90 (GL-6), or SAE140 (GL-5)

0.2 L (0.2 US qt)

Oil Level Filler opening level

NOTE

○

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

•

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

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

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

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

•

Tilt up the front cargo hood.

•

Remove:

Rubber Cap [A]

Front Cargo Compartment [B]



•

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

Upper Level Line (MAX)

Lower Level Line (MIN) [B]

•

Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

WARNING

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


Brake Fluid Change

•


•

Remove:

Rubber Cap

Brake Fluid Reservoir Cap

•

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 Wheels/Tires chapter).

•

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.

Brake Panel [B]

NOTE

○

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




•

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: 8.0 N·m (0.82 kgf·m, 71 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

Brakes chapter).

WARNING

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

•

Install the removed parts.

Torque - Master Cylinder Reservoir Cap: 3.4 N·m (0.35


Brake Pedal Play Inspection

•

Check brake pedal free play [A].

Brake Pedal Free Play

Standard: 2

∼

5 mm (0.08

∼

0.20 in.)

If free play is not correct, adjust it.

•

Remove the front cargo compartment (see 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: 18 N·m (1.8 kgf·m, 13 ft·lb)

•

Check the brake for good braking power and no brake drag.

WARNING

Incorrect adjustment with insufficient free play can cause brake heating and drag. Skidding and loss of control may result.



Brake Master Cylinder Cup and Dust Seal

Replacement

•

Remove the master cylinder (see Master Cylinder Removal in the Brakes chapter).

•

Remove the piston stop bolt [A] and washer [B].

•

Remove the dust seal [C] and then the retainer [D] 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 [E]

Springs [F]

Secondary Cup [G]

Primary Cup [H]

Master Cylinder [I]

○

Be careful of the secondary cup [A] direction [B].


•

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.

CAUTION

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

○

Push the 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: 6.2 N·m (0.63 kgf·m, 55 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 in this section).

Brake Hose and Pipe Replacement

•

Remove:

Front Cargo Compartment (see Frame chapter)

Left and Right Side Cover (see Frame chapter)

Floor Center Panel (see Frame chapter)

Wheels (see Wheels/Tires chapter)

•

Drain the brake fluid.

•

Remove:

Nipple [A] and Brake Pipe [B]

Banjo Bolts [C] and Brake Hose [D]

•

Immediately wipe up any brake fluid that spills.

CAUTION

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

•

Remove:

Nipples [A]

Retainers [B]

Brake Pipes [C]

Brake Hose [D]

•

Remove:

Brake Pipe [A]



•

Remove:

Wheels

Nipple [A]

Retainer

Brake Pipe [B]

•

Use new copper washers [A] for each side of the hose fittings at the master cylinder.

•

Tighten:

Torque - Brake Hose Banjo Bolts [B]: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Install the brake pipe [A] and tighten the nipple [B].

Torque - Brake Pipe Nipple: 18 N·m (1.8 kgf·m. 13 ft·lb)

•

Fill the reservoir with new brake fluid (see Brake Fluid

Change).

•

Check that the brake line has proper fluid pressure and no fluid leakage.

•


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: 165.00

∼

165.16 mm (6.4961

∼

6.5023

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 mm (0.16 in.)

Service Limit: 1 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.

CAUTION

Do not use a solvent which will leave an oily residue or the shoes will have to be replaced.

Brake Wheel Cylinder Assembly Replacement

•

Remove:

Brake Drum (see Brake Drum Removal in the Brakes chapter.)

•

Remove the brake shoe spring [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.

○


CAUTION


•

Unscrew the mounting bolts [B] and take off the front brake wheel cylinder [C].



•

Replace the rear wheel cylinder with a new one.

•

Apply liquid gasket to the hatched area [A].

Sealant - Three Bond: 1109


•

Tighten:

Torque - Wheel Cylinder Mounting Bolts: 12 N·m (1.2

kgf·m, 106 in·lb)

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

•

Install the removed parts (see Brake Panel Assembly section in the brakes chapter).

•

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

Do not attempt to drive the vehicle until a full brake pedal is obtained. Pump the brake pedal until the wheel cylinders operate and the brake shoes are against the drums. The brake will not function on the first application of the pedal if this is not done.

•

Adjust:

Parking Brake Lever (see Parking Brake Lever Inspection in this section)

•

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)

•

Release the parking brake and return the lever to its rest position.

If the lever travel is not correct, adjust it.

•

Loosen the locknut [A] and turn the adjusting nut [B] 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

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




NOTE

○

If the parking brake lever travel cannot be adjusted with the adjusting nut at the lever, use the adjusters [A] behind the parking brake lever. Be sure to adjust both the left and right cables evenly, and then securely tighten the adjuster mounting nuts [B].

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 chapter)

Intermediate Shaft Clamp Bolts (see Steering chapter)

Steering Gear Assembly Mounting Bracket Bolts (see

Steering chapter)

Steering Gear Assembly Mounting Rubber Dampers

Tie-rod End Nuts (see Wheels/Tires chapter)

Steering Gear Preload Adjustment (see Steering 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.

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



Frame

Seat Belt Inspection

•

Check the belt [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)


•

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.


Spark Plug Cleaning/Inspection

•

Remove the spark plug (see Electrical System chapter).

•

Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool.

If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

Spark Plug Gap Inspection

•

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

If the gap is incorrect, carefully bend the side electrode

[B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

0.7

∼

0.8 mm (0.028

∼

0.032 in.)

Electrolyte Level Inspection

•

The electrolyte level should be between the upper and lower level lines [A].

If the level of electrolyte in any cell is below the lower level line, add only distilled water to the cell, until the level is at the upper level line.

CAUTION

Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.




Electrolyte Specific Gravity Inspection

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 of the electrolyte [A] on the floating scale.

Specific Gravity

Standard: 1.270 @20°C (68°F)

If the specific gravity is below 1.200 (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 above 20°C or subtract 0.007 points for each 10°C below 20°C

○

Fahrenheit: Add 0.004 points to reading for each 10°F above 68°F or subtract 0.004 points for each 10°F below 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 1.270 or more, the battery is fully charged.

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 (0.4 in.) of pedal travel [A].

If it does not, adjust the brake light switch [A] up or down.

To change the switch position, turn the adjusting nut [B].

Brake Light Switch Timing

Standard: ON after 10 mm (0.39 in.) of pedal travel

CAUTION

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



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.

Seat Brackets

Cargo Bed Mounting Pins

Throttle Pedal Pivot

Brake Pedal Pivot

Transmission Shift Control Lever Pivot

Differential Shift Cable Upper End

2WD/4WD Shift Lever Pivot (KAF400-A/C)

Cables: Lubricate with Rust Inhibitor.

Throttle Cable

Differential Shift Cable

2WD/4WD Shift Cable (KAF400-A/C)

Cables: Lubricate with Motor Oil.

Parking Brake Cables

•

With the cable disconnect at both ends, the cable should move freely [A] within the cable housing.

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




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

(see Torque and Locking Agent in this chapter).

If cotter pins are damaged or removed, replace them with new ones.

Nut, Bolt, and Fasteners to be checked

Engine

Engine Mounting Bolts

Exhaust Pipe Holder Nuts

Exhaust Pipe and Muffler Clamp Bolt


Throttle Pedal Pivot Clip

Fuel Tank Holder Nuts

Transmission/Final Drive

Axle Nuts and Cotter Pins

Drive Shaft Bracket Mounting Nuts

Transmission Shift Cable Upper End Clip

Transmission Shift Lever Clamp Bolt

Differential Shift Lever Pivot Clip

Differential Shift Cable Upper End Clip

Differential Shift Lever Mounting Nut

Front Final Gear Case Mounting Nuts (KAF400-A/C)

Front Final Gear Case Bracket Bolts (KAF400-A/C)

Propeller Shaft Bearing Mounting Nuts (KAF40-0A/C)

2WD/4WD Shift Lever Pivot Clip (KAF400-A/C)

2WD/4WD Shift Lever Mounting Nut (KAF400-A/C)

Hi/Low Shift Lever Pivot Clip

Hi/Low Shift Cable Upper End Clip

Hi/Low Shift Lever Mounting Nut

Wheels

Wheel Nuts

Brakes

Master Cylinder Mounting Bolts

Master Cylinder Push Rod Clevis Pin Clip

Parking Brake Lever Assembly Mounting Bolts

Brake Pedal Pivot Shaft Cotter Pin

Suspension

Suspension Arm Pivot Bolts

Strut Mounting Nuts

Strut Clamp Nuts and Cotter Pins

Shock Absorber Mounting Nuts

Swing Unit Joint Nut

Swing Unit Rod Mounting Nuts



Steering

Steering Wheel Mounting Nut

Intermediate Shaft Clamp Bolts

Tie-rod End Nuts and Cotter Pins

Tie-rod End Locknuts

Steering Knucle Pivot Nuts

Steering Gear Assembly Mounting Bolts

Suspension Arm Joint Nuts and Cotter Pins

Main Shaft Mounting Bolts and Nuts

Frame

Front and Rear Bar Mounting Bolts and Nuts

Front Guard Mounting Nuts

Cargo Bed Hook Mounting Bolts

Cargo Bed Mounting Pin Clips

Screen Mounting Nuts

Seat Bracket Nuts and Bolts

Seat Back Mounting Nuts

Seat Belt Mounting Bolts

Battery Holder Nuts




FUEL SYSTEM 3-1

Fuel System

Exploded View...................................

Specifications ....................................

Throttle Pedal and Cable...................


Inspection..................................


Adjustment ................................

Full Throttle Pedal Position

Adjustment ................................

Throttle Cable Installation ............

Throttle Cable Lubrication............

Throttle Cable Inspection .............

Governor Link Mechanism.................

Control Panel Assembly Removal

Control Panel Assembly

Installation .................................

Governor Assembly Removal ......

Governor Assembly Installation ...

Governor Assembly Inspection ....

Choke Cable......................................

Choke Knob Free Play Inspection

Choke Knob Free Play

Adjustment ................................

Choke Cable Installation ..............

Choke Cable Lubrication..............

Choke Cable Inspection...............

Carburetor .........................................

Idle Speed Inspection ..................

Idle Speed Adjustment.................


3-8

3-12

3-12

3-12

3-13

3-13

3-13

3-13

3-13

3-14

3-15

3-15

3-15

3-7

3-7

3-7

3-7

3-8

3-8

3-2

3-6

3-7

3-7

3-7

Fuel System Cleanliness

Inspection..................................

Carburetor Removal.....................

Carburetor Installation..................

Carburetor Disassembly ..............

Carburetor Assembly ...................

Carburetor Cleaning.....................

Carburetor Inspection ..................

Pilot Screw Setting.......................

Air Cleaner.........................................

Air Cleaner Element Removal......

Air Cleaner Element Installation...

Air Cleaner Housing Removal......

Air Cleaner Housing Installation...

Air Cleaner Housing Dust and/or

Water Installation ......................

Fuel Pump .........................................

Fuel Pump Removal ....................

Fuel Pump Installation .................

Fuel Pump Inspection ..................

Fuel Filter...........................................

Fuel Filter Removal......................

Fuel Filter Installation...................

Fuel Filter Inspection....................

Fuel Tank ...........................................

Fuel Tank Removal ......................

Fuel Tank Installation ...................

Fuel Tank Cleaning/Inspection.....

3-19

3-20

3-21

3-21

3-21

3-21

3-22

3-15

3-15

3-16

3-16

3-18

3-19

3-22

3-23

3-23

3-23

3-23

3-25

3-25

3-25

3-25

3-26

3-26

3-26

3-26

3


3-2 FUEL SYSTEM

Exploded View


Exploded View

No.

Fastener

1 Air Cleaner Housing Bolts

2 Carburetor Mounting Nuts

3 Choke Valve Screws

4 Throttle Valve Screws

5 Pilot Jet

6 Pilot Jet Plug

7 Main Jet

8 Drain Screw

9 Float Chamber Bolt

10. Pilot Screw

11. Idle Adjustung Screw

12. Choke Cable

13. Throttle Cable

G: Apply grease.

L: Apply a non-permanent locking agent.


FUEL SYSTEM 3-3

N·m

17

6.9

0.90

0.90

0.70

2.5

2.0

2.0

9.8

Torque kgf·m

1.7

0.70

0.09

0.09

0.07

0.25

0.20

0.20

1.0

ft·lb

12

61 in·lb

7.8 in·lb

7.8 in·lb

6.1 in·lb

22 in·lb

17 in·lb

17 in·lb

87 in·lb

Remarks

L

L


3-4 FUEL SYSTEM

Exploded View


Exploded View

No.

Fastener

1 Panel Cover Bolts

2 Control Panel Bolt

3 Plate Connection Bolts

4 Control Panel Mounting Bolts

5 Governor Arm Nut

6 Fuel Pump Mounting Bolts

7 Air Cleaner Housing Bolts

8 Fuel Pump Bracket Bolt

9 Breather Mounting Bolt

10 Brearher Bracket Bolt

11. Governor

12. Fuel Pump

13. Fuel Filter

FUEL SYSTEM 3-5

N·m

4.4

6.9

8.8

20

5.9

5.4

17

5.4

8.8

15

Torque kgf·m

0.45

0.70

0.90

2.0

0.60

0.55

1.7

0.55

0.90

1.5

ft·lb

39 in·lb

61 in·lb

78 in·lb

14

52 in·lb

48 in·lb

12

48 in·lb

78 in·lb

11

Remarks


3-6 FUEL SYSTEM

Specifications

Item

Throttle Pedal and Cable


Choke Cable

Choke Knob Free Play

Carburetor

Idle Speed

Carburetor Specifications:

Make/Type

Main Jet

Pilot Jet (Slow Jet)

Pilot Screw (turns out)

Standard

2

∼

5 mm (0.08

∼

0.20 in.)

0

∼

1 mm (0

∼

0.04 in.) about 1 100

∼

1 250 r/min (rpm)

NIKKI 6C1026

#112

#54

3 1/2 ±3/8

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –


Throttle Pedal and Cable

Throttle Pedal Free Play Inspection

•

Refer to the Throttle Pedal Free Play Inspection in the

Periodic Maintenance chapter.

Throttle Pedal Free Play Adjustment

•

Refer to the Throttle Pedal Free Play Adjustment in the


Full Throttle Pedal Position Adjustment

•

Loosen the locknut [A].

•

Screw in the throttle pedal stop bolt [B].

•

Depress the throttle pedal [C] until the throttle lever on the carburetor is in the fully opened position, and keep its position.

•

Turn the throttle pedal stop bolt until the bolt head lightly touches the bottom of the throttle pedal.

•

Tighten the locknut securely.

Throttle Cable Installation

•

Lubricate the throttle cable before installation.

•

Route the throttle cable correctly (see Appendix chapter).

•

Adjust:

Throttle Pedal Free Play Adjustment

WARNING

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

Throttle Cable Lubrication

•

Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Maintenance chapter, lubricate the cable.

•

Refer to the General Lubrication in the Periodic Maintenance chapter.

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, or if the housing is kinked, replace the cable.

FUEL SYSTEM 3-7


3-8 FUEL SYSTEM

Governor Link Mechanism

Control Panel Assembly Removal

•


•

Drill out the pop rivets [A] holding the control panel assembly shroud [B] with a drill bit of the 5 mm (0.02 in.) diameter.

○

Drill only until the rivet head comes off.

Do not drill through the hole.

•

Remove:

Link [A]

Governor Spring [B]

Plate Connection Bolts [C]

Control Panel Mounting Bolts [D]

Control Panel Assembly [E]

Control Panel Assembly Installation

•

Install:

Control Panel Assembly

•

Tighten:

Torque - Control Panel Mounting Bolts: 20 N·m (2.0 kgf·m,

14 ft·lb)

Plate Connection Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Insert the bushing [A] in the hole of the governor arm with click [B].

•

Insert the link [A] in the hole of the bushing [B] from upper side.



•

Turn the bushing [A] counterclockwise until fitting on the link with click [B].

FUEL SYSTEM 3-9

•

Hold the carburetor throttle full open [A], tighten the governor nut [B] with pivot arm [C] and governor arm [D] are turned fully clockwise.

○

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

Snap Pins [F]

•

Install:

Governor Spring [A]

Return Spring [B]

Throttle Cable [C]

•

Temporarily tighten the throttle cable mounting nuts [D].


3-10 FUEL SYSTEM


•

Screw in the accel lever stopper screw [A] until it keeps clearance by 1 mm (0.04 in.) [B] to the accel lever [C] at idle speed position.

Idle Speed about 1 100

∼

1 250 r/min (rpm)

•

Tighten the throttle cable mounting nuts [D].

○

In this case, do not extend the cable too much.

○

The idle screw [E] must contact to link lever [F].

•

Check that the governor arm [G] and accel lever pin [H] touch lightly, when the throttle lever (accel pedal) is fully opened.

•

Adjust:


Idle Speed Adjustment

•

Install the control panel assembly shroud with pop rivets.



FUEL SYSTEM 3-11

1. Governor Arm

2. Link

3. Governor Spring

4. Bushing

5. Control Panel

6. Collars

7. Throttle Cable

8. Washer

9. Governor Arm Clamp Nut




Governor Assembly Removal

•

Remove:

Transmission Case (split)

Transmission Shafts

Governor Shaft Snap Pins [A]

Governor Shaft [B]

Washer (thin) [C]

Washer (thick) [D]

•

Remove the governor assembly [A] with the sleeve [B] by prying the gear [C] with two suitable levers.

CAUTION

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

•

Remove the washer.

Governor Assembly Installation

•

Fit the sleeve into the governor assembly, and install them as a set.

NOTE

○

The sleeve and the governor assembly cannot be installed separately.

○

Push the set onto the shaft until the step fits into the groove securely.

Sleeve [A]

Governor Assembly [B]

Step [C]

Washer [D]

Groove [E]

Shaft [F]

32 mm (1.26 in.) [G]

•

Check that the gear turns freely and the weights [H] move smoothly.

Governor Assembly Inspection

•

Visually check the governor assembly [A] for wear and damage.

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



Choke Cable

Choke Knob Free Play Inspection

•

Check that the choke knob returns properly and that the inner cable slides smoothly.

•

Remove:


•

Push in the choke knob all the way.

•

Check the choke cable free play [A].

○

Determine the amount of free play at the choke knob. Pull the choke knob until the starter lever [A] on the carburetor begins to turn; the amount of choke knob travel is the amount of free play.

If the free play is not correct, adjust the choke cable.

Choke Knob Free Play

Standard: 0

∼

1 mm (0

∼

0.04 in.)

Choke Knob Free Play Adjustment

•

Remove:


•

Loosen the mounting nuts [A] and slide the adjuster [B] until the cable has the proper amount of free play.

•

Tighten the mounting nuts securely.

Choke Cable Installation

•

Lubricate the throttle cable before installation.

•

Route the choke cable correctly (see the Appendix chapter).

•

Adjust:

Choke Cable Free Play Adjustment

WARNING

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

Choke Cable Lubrication

•

Whenever the choke cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Maintenance chapter, lubricate the cable.

•




Choke Cable

Choke Cable Inspection

•

With the choke 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, or if the housing is kinked, replace the cable.


Carburetor

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.

Fuel System Cleanliness Inspection

•

Refer to the Fuel System Cleanliness Inspection in the


Carburetor Removal

WARNING


•

Remove:

Cargo Bed (tilt up)


Choke Cable Lower End [A]

Breather Hose [B]

Fuel Hose [C]

Mounting Nuts [D] and Washers

Intake Pipe [E]

Choke Cable Bracket [F]

•

Remove:

Carburetor [A]

Throttle Link [B]


•

After removing the carburetor, stuff pieces of lint-free, clean cloth into the carburetor holder and the air cleaner duct to keep dirt out of the engine and air cleaner.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.



Carburetor

Carburetor Installation

•

Install:

New Gasket [A]

Insulator [B]

Carburetor [C]

○

When installing the carburetor, install the throttle link.

•

Install:

New Gasket [D]

Bracket [E] (as shown)

Intake Pipe [F]

Washers [G] and Mounting Nuts [H]

Torque - Carburetor Mounting Nuts: 6.9 N·m (0.70 kgf·m,

61 in·lb)

•

Install the parts removed.

•

Adjust:


Choke Cable Free Play Adjustment

Idle Speed Adjustment

Carburetor Disassembly

WARNING


•

Remove:

Carburetor (see Carburetor Removal)

Float Chamber Mounting Bolt [A] and Gasket

Float Chamber [B]


Carburetor

•

Remove:

Pin [A]

Float [B] and Float Valve Needle

•

Remove:

Main Jet [A]

•

Remove:

Pilot Jet Plug [A]

•

Remove:

Pilot Jet [A]




Carburetor

Carburetor Assembly

•

Replace the following parts with new ones.

Circlip [A]

Cap [B]

Dust Seal [C]

Gaskets [D]

•

Apply a non-permanent locking agent:

Choke Valve Screws [E]

Throttle Valve Screws [F]

•

Tighten:

Torque - Choke Valve Screws: 0.90 N·m (0.09 kgf·m, 7.8

in·lb)

Throttle Valve Screws: 0.90 N·m (0.09 kgf·m, 7.8

in·lb)

Pilot Jet [G]: 0.70 N·m (0.07 kgf·m, 6.1 in·lb)

Pilot Jet Plug [H]: 2.5 N·m (0.25 kgf·m, 22 in·lb)

Main Jet [I]: 2.0 N·m (0.20 kgf·m, 17 in·lb)

Drain Screw [J]: 2.0 N·m (0.20 kgf·m, 17 in·lb)

Float Chamber Bolt [K]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install:

Choke Valve [L]

Springs [M]

Anti Tamper Plug [N]

Idle Adjusting Screw [O]

Throttle Valve [P]

Collars [Q]

Float Valve Needle [R]

Pin [S]

Float [T]


Carburetor

Carburetor Cleaning

WARNING

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

CAUTION

Do not use compressed air on an assembled carburetor, the float may be crushed by the pressure.

Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high flash point cleaning solution safe for plastic parts.

Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

•

Disassemble the carburetor.

•

Immerse all the metal parts in a carburetor cleaning solution.

•

Rinse the parts in water.

•

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

•

Blow through the air and fuel passages with compressed air.

•

Assemble the carburetor.

Carburetor Inspection

WARNING


•

Turn the throttle and choke shafts to check that the throttle and choke valves move smoothly.

Throttle Valve [A]

Choke Valve [B]

If the valves do not more smoothly, replace the damaged parts.




Carburetor

•

Check the float [A] for cracks.

If there are any cracks, replace the float.

NOTE

○

Float height can not be adjusted.

•

Check the tip [A] of the float valve needle [B]. It should be smooth, without any grooves, scratches, or tears.

If the tip is damaged replace the valve needle.

Pilot Screw Setting

CAUTION

Do not turn the pilot screw. You may cause poor running at low engine speed. Do not force or overtighten the pilot screw. It could be damaged requiring replacement.

○

The pilot screw [A] is set at the factory and should not be adjusted, But if necessary, set the pilot screw as follows:

•

Remove:

Carburetor (see Carburetor Removal)

•

Punch a hole in the plug [B] and pry it out with an awl or other suitable tool.

•

Turn in the pilot screw and count the number of turns until it seats fully but not tightly.

○

Back out the same number of turns counted when turned in. This is to set the screw to its original position.

NOTE

○

A carburetor has different “turns out” of the pilot screw for each individual unit. When setting the pilot screw, use the “turns out” determined during disassembly. Use the specifications in this manual only if the original number is unknown.

•

Remove the pilot screw, and set the pilot screw using a screwdriver.

•

Install a new plug in the pilot screw hole of the carburetor body, and apply a little bonding agent [C] to the circumference of the plug to fix the plug.

CAUTION

Do not apply too much bonding agent to the plug or

Air Cleaner

Air Cleaner Element Removal

•

Tilt up the Seat.

•

Unhook the clamps [A].

•

Remove:

Air Cleaner Cover [B]

•

Loosen:

Clamp Screw [A]

•

Remove:

Mounting Screw [B]

Air Cleaner Element [C]

•

After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner duct to keep dirt out of the carburetor and engine.

WARNING

If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly causing an accident.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Air Cleaner Element Installation

•

Apply grease to the dust seal [A].

•

Install the element.

•

Tighten:

Mounting Screw

Clamp Screw

Air Cleaner Housing Removal

•

Remove:


Air Cleaner Ducts [A]




Air Cleaner

•

Remove:

Fuel Pump Bracket Bolt [A]

Air Cleaner Housing Bolts [B]

Air Cleaner Housing [C]

Air Cleaner Housing Installation

•

Tighten:

Torque - Air Cleaner Housing Bolts: 17 N·m (1.7 kgf·m, 12 ft·lb)

Fuel Pump Bracket Bolt: 5.4 N·m (0.55 kgf·m, 48 in·lb)

•

Install the air cleaner ducts and tighten the clamps.

Air Cleaner Housing Dust and/or Water Installation

If you see any dust and/or water accumulated in the housing, remove the drain cap [A] at the bottom of the air cleaner housing [B] and expel it.

[C] Clamp


Fuel Pump

Fuel Pump Removal

WARNING


•

Tilt up the Seat.

•

Remove:

Fuel Hoses [A]

Vacuum Hose [B]

Fuel Pump Mounting Bolts [C]

Fuel Pump [D]

Fuel Pump Installation

•

Install:

Fuel Pump

Fuel Pump Mounting Bolts

•

Tighten:

Torque - Fuel Pump Mounting Bolts: 5.4 N·m (0.55 kgf·m,

48 in·lb)

•

Install:

Fuel Hose (Fuel Tap Side) [A]

Vacuum Hose [B]

Fuel Hose (Carburetor Side) [C]

Clamps [D]

Fuel Pump Inspection

•

Remove the fuel pump (see Fuel Pump Removal).

If the hose connection areas [A] of the fittings are damaged, replace the fuel pump.




Fuel Pump

•

Blow the air to the outlet fitting [A], and make sure does not flow the blown air from the inlet fitting [B].

If the fuel pump does not operate as described, replace it with a new one.

•

Inhale the air to the inlet fitting [A], and make sure does not inhale the blown air from the outlet fitting [B].

If the fuel pump does not operate as described, replace it with a new one.


Fuel Filter

Fuel Filter Removal

WARNING


•

Refer to Fuel Filter Replacement in the Periodic Maintenance chapter.

Fuel Filter Installation

•

Refer to Fuel Filter Replacement in the Periodic Maintenance chapter.

Fuel Filter Inspection

•

Visually inspect the fuel filter.

If the filter is clear with no signs of dirt or other contamination, it is OK and need not be replaced.

If the filter is dark or looks dirty, replace it. Also, check the rest of the fuel system for contamination.




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:

Right Side Cover (see Frame chapter)

Fuel Hose [A] (disconnect)

Fuel Tank Bolt [B], Washer and Nut

Fuel Tank [C]

Fuel Tank Installation

•

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

•

Install:

Damper [A]

Collar [B]

Washer [C]

Fuel Tank Bolt [D]

Nut [E]

Fuel Tank Cleaning/Inspection

WARNING

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

•

Remove the fuel tank and drain it.

•

Remove the fuel level gauge [A].

•

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 gaskets on the fuel level gauge and fuel tank cap for any damage.

Replace the gaskets if they are damaged.


ENGINE TOP END 4-1

Engine Top End


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Cylinder Head ........................................................................................................................

Cylinder Compression Measurement................................................................................

Cylinder Head Removal ....................................................................................................

Cylinder Head Installation .................................................................................................

Push Rod Inspection.........................................................................................................

Valve Mechanism Removal/Installation ............................................................................

Rocker Arm Inspection......................................................................................................

Cylinder Head Warp..........................................................................................................

Valves .....................................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance Adjustment.............................................................................................

Valve Seat Inspection .......................................................................................................

Valve Seat Repair .............................................................................................................

Valve Spring Free Length .................................................................................................

Valve Head Thickness ......................................................................................................

Valve Stem Bend ..............................................................................................................

Valve Stem Diameter ........................................................................................................

Valve Guide Inside Diameter ............................................................................................

Measuring Valve/Guide Clearance (Wobble Method) .......................................................

Exhaust Pipe and Muffler .......................................................................................................

Exhaust Pipe Removal......................................................................................................

Muffler Removal................................................................................................................

Exhaust Pipe and Muffler Installation................................................................................

Exhaust Pipe and Muffler Inspection ................................................................................

Spark Arrester Cleaning....................................................................................................

4-12

4-15

4-15

4-15

4-15

4-16

4-16

4-17

4-17

4-17

4-18

4-18

4-18

4-9

4-9

4-9

4-10

4-11

4-11

4-11

4-11

4-2

4-4

4-5

4-6

4-6

4-6

4-7

4


4-2 ENGINE TOP END

Exploded View


Exploded View

No.

Fastener

7

8

5

6

3

4

1

2

Cylinder Head Cover Bolts

Cylinder Head Bolts

Engine Shroud Bolts

Valve Adjusting Nut Lock Screw

Rocker Arm Bolts

Exhaust Pipe Clamp Nuts

Muffler Clamp Nuts


EO: Apply engine oil.

M: Apply molybdenum disulfide grease.


S: Follow the specific tightening sequence.


N·m

6.9

37

5.9

6.9

28

20

31

31

Torque kgf·m

0.70

3.8

0.60

0.70

2.9

2.0

3.2

3.2

ft·lb

61 in·lb

27

52 in·lb

61 in·lb

21

14

23

23

Remarks

S



Specifications

Item

Cylinder Head

Standard

Cylinder Compression (Usable Range)

340

∼

590 kPa (3.5

∼

6.0 kgf/cm², 50

∼

85 psi) @530 r/min (rpm)

Rocker Arm Push Rod Runout – – –

Service Limit

– – –

TIR 0.5 mm (0.02 in.)

Cylinder Head Warp – – – 0.03 mm (0.001 in.)

Valves

Valve Clearance (when cold) 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.) – – –

Valve Seating Surface:

Outside Diameter:

Inlet

Exhaust

32.8 mm (1.291 in.)

27.6 mm (1.087 in.)

– – –

– – –

Width:

Inlet

Exhaust

Valve Seat Cutting Angle

Valve Spring Free Length

Valve Head Thickness

1.1

∼

1.7 mm (0.043

∼

0.070 in.)

1.0

∼

1.5 mm (0.039

∼

0.059 in.)

45°

35 mm (1.38 in.)

0.4 mm (0.016 in.)

– – –

– – –

– – –

32.6 mm (1.28 in.)

0.4 mm (0.016 in.)

Valve Stem Bend Less than 0.01 mm (0.0004 in.) TIR TIR 0.05 mm (0.0020 in.)

Valve Stem Diameter:

Inlet

Exhaust

6.960

∼

6.975 mm (0.2740

∼

0.2746 in.) 6.95 mm (0.274 in.)

6.945

∼

6.960 mm (0.2734

∼

0.2740 in.) 6.93 mm (0.273 in.)

Valve Guide Inside Diameter 7.000

∼

7.015 mm (0.2756

∼

0.2762 in.) 7.08 mm (0.279 in.)

Valve/guide Clearance

(wobble method):

Inlet

Exhaust

0.06

0.10

∼

∼

0.13 mm (0.0024

0.17 mm (0.0039

∼

∼

0.0051 in.)

0.0067 in.)

0.29 mm (0.011 in.)

0.33 mm (0.013 in.)


Special Tools

Compression Gauge, 20 kgf/cm²:

57001-221


Valve Seat Cutter, 32° 38.5:

57001-1122

Valve Seat Cutter, 45° 32:

57001-1115


57001-1116


57001-1121

Valve Seat Cutter Holder, 7:

57001-1126

Valve Seat Cutter Holder Bar:

57001-1128

Compression Gauge Adapter, M14 × 1.25:

57001-1159



Cylinder Head

Cylinder Compression Measurement

•


•

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 spark plug, and attach a compression gauge [A] firmly into the spark plug hole.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221

Compression Gauge Adapter, M14 × 1.25

[B]: 57001-1159

•

Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; this is the highest compression reading obtainable.

Cylinder Compression

Usable Range:

340

∼

590 kPa (3.5

∼

6.0 kgf/cm², 50

∼

85 psi) @530 r/min (rpm)

•

Repeat the measurement to the other cylinder.

The following table should be consulted if the obtainable compression reading is not within the usable range.

Remedy (Action)

Remove the carbon deposits and replace damaged parts if necessary.

Cylinder compression higher than usable range

Problem 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

Incorrect cylinder head gasket thickness

Gas leakage around cylinder head Cylinder compression lower than usable range

Bad condition of valve seating

Incorrect valve, piston/cylinder clearance

Piston seizure

Bad condition of piston ring and/or piston ring grooves

Replace with a gasket of the proper thickness.

Replace damaged gasket and check cylinder head warp.

Repair if possible.

Adjust.

Inspect cylinder and liner and replace/repair as necessary.

Replace.

Cylinder Head Removal

•

Remove:

Cargo Bed (see Frame chapter)

Carburetor (see Fuel System chapter)

Alternator Cover (see Alternator Removal in the Electrical System chapter)

Bolts [A]

Tank [B]

Engine Shroud [C]


Cylinder Head

•

Remove:

Spark Plug Cap [A]

Oil Level Gauge [B]

Cylinder Head Cover Bolts [C]

Cylinder Head Cover [D]

•

Position the crankshaft at TDC of the end of the compression stroke.

•

Loosen:

Lock Screws [A]

•

Remove:

Valve Clearance Adjusting Nuts [B]

Rocker Arm [C]

Push Rods [D]

•

Remove:

Cylinder Head Bolts [A]

Push Rod Guides [B]

Cylinder Head [C]


Cylinder Head Installation

•

Clean the mating surface of the cylinder head and the cylinder.

•

Install the dowel pins [A].

•

Replace the gasket [B] with a new one.

•

Install:

Cylinder Head

Push Rod Guides [A]



Cylinder Head

•

Tighten the cylinder head bolts following the tightening sequence as shown.

Torque - Cylinder Head Bolts: 37 N·m (3.8 kgf·m, 27 ft·lb)

•

Apply engine oil to the push rods [A] and install them onto the tappet [B].

○

To install the push rods [A] in the correct positions on the tappets [B], insert the push rod [A] so that the end of the push rod is sliding down along inside wall [C] of the crankcase and position the push rod end on to the tappet.

○

Check both inlet and exhaust push rods on each cylinder are lowest position on the cam lobes [D]. If not, turn the alternator rotor clockwise one turn and position the crankshaft at TDC of the compression stroke.

○

Be sure the end of the push rods are correctly seated on the tappets.

•

Apply engine oil to the rocker arms.

•

Install:

Rocker Arms

Valve Clearance Adjusting Nuts

•

Check and adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).

•

Install:

New Gasket

Cylinder Head Cover

•

Tighten:

Torque - Cylinder Head Cover Bolts: 6.9 N·m (0.70 kgf·m,

61 in·lb)

Engine Shroud Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)


Cylinder Head

Push Rod Inspection

•

Place the rocker arm push rod in V blocks that are as far apart as possible, and set a dial gauge [A] on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings is the amount of runout.

If the runout exceeds the service limit, replace the rod.

Rocker Arm Push Rod Runout

Service Limit: TIR 0.5 mm (0.02 in.)

Valve Mechanism Removal/Installation

•

Remove:

Cylinder Head (see Cylinder Head Removal)

•

Support the valve head in the combustion chamber with a suitable block.

•

To remove the collets [A], push down the valve retainer

[B] with thumbs and remove the collets.

•

Remove the valve retainer, spring [C] and valve [D] .

•

Remove the stem seals [A].

NOTE

○

It is not necessary to remove the stem seal unless it is being replaced.

○

Valve guide [B] is not replaceable, do no remove it.

•

Apply engine oil to the valve stems and install them.

•

Check to see that the valve moves smoothly up and down in the guide.

•

Install the spring and the valve retainer.

•

Install the valve retainer while push down the valve retainer with the thumbs.

•

Install:

Cylinder Head (see Cylinder Head Installation)

Rocker Arm Inspection

•

Clean and inspect the rocker arm where it touches the push rod and valve stem.

If the contact points [A] are worn or damaged, replace the rocker arm.




Cylinder Head

Cylinder Head Warp

•

Lay a straightedge [A] across the lower 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



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


Valve Seat Inspection

•

Remove the valve.

•

Check the valve seating surface [A] between the valve [B] and valve seat [C].

•

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 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 [D] 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 Outside Diameter

Inlet: 32.8 mm (1.291 in.)

Exhaust: 27.6 mm (1.087 in.)

•

Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper.

Good [F]

Too Wide [G]

Too Narrow [H]

Uneven [J]

If the width is too wide, too narrow or uneven, repair the seat (See Valve Seat Repair).

Valve Seating Surface Width Standard

Inlet: 1.1

∼

1.7 mm (0.043

∼

0.070 in.)

Exhaust: 1.0

∼

1.5 mm (0.039

∼

0.059 in.)




Valves

Valve Seat Repair

•

Follow the manufacturer’s instructions for use of valve seat cutters.

Special Tools - Valve Seat Cutter, 45° 35: 57001-1116 [IN]

Valve Seat Cutter, 32° 38.5:

57001-1122 [IN]


57001-1115 [EX]


57001-1121 [EX]

Valve Seat Cutter Holder, 7: 57001-1126

Valve Seat Cutter Holder Bar: 57001-1128

If the manufacture’s instructions are not available, use the following procedure.

Seat Cutter Operating Cares

1. The valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes.

2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off.

3. Do not fail to apply engine oil 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 [A] in position, operate the cutter [B] with one hand [C]. Do not apply too much force to the diamond portion.

NOTE

○

Prior to grinding, apply oil to the cutter, and during the operation wash off any ground particles sticking to the cutter with washing oil.

5. After use wash the cutter with washing oil and apply a thin layer or 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 to the holder and slide it into the valve guide.

•

Press down lightly on the handle and turn it right or left.

Grind the seating surface only until it is smooth.

CAUTION

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 (O.D.) of the seating surface with a vernier caliper.

If the O.D. of the seating surface is too small, repeat the

45° grind until the diameter is within the specified range.

If the O.D. of the seating surface is too large, make the

32° grind described below.

•

Grind the seat at a 32° angle until the seat O.D. is within the specified range.

○

To make the 32° grind, fit a 32° cutter to 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.

CAUTION

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 O.D. measurement step above.

•

Lap the valve to the seat, once the seat width and O.D.

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.

[A] Lapper

[B] Valve Seat

[C] Valve

•

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 clearances (see Valve Clearance Adjustment).



Valves


Valves

Valve Spring Free Length

•

Measure the valve spring [A] free length.

If the free length is less than the service limit, replace the valve spring with a new one.

Valve Spring Free Length



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: 0.4 mm (0.016 in.)


Valve Stem Bend

•

Place the valve in V blocks at each end of the stem, and set a dial gauge [A] on the stem at a point halfway between the blocks. Turn the valve to measure the bend.

The difference between the highest and the lowest dial readings is the amount of bend.

If the valve stem bend is greater than the service limit, replace the valve with a new one.

Valve Stem Bend

Standard: Less than 0.01 mm (0.0004 in.) TIR


Valve Stem Diameter

•

Measure the diameter of the valve stem [A] in two directions at right angles, at four different positions on the stem.

If any single measurement is less than the service limit, replace the valve with a new one.

Valve Stem Diameter

Standard:

Inlet

Exhaust

6.960

∼

6.975 mm (0.2740

∼

0.2746 in.)

6.945

∼

6.960 mm (0.2734

∼

0.2740 in.)

Service Limit:

Inlet 6.95 mm (0.274 in.)

Exhaust 6.93 mm (0.273 in.)




Valves

Valve Guide Inside Diameter

•

Measure the inside diameter [A] of the valve guide [B].

If the valve guide has worn past the service limit, replace the cylinder head.

Valve Guide Inside Diameter

Standard: 7.000

∼

7.015 mm (0.2756

∼

0.2762 in.)


Measuring Valve/Guide Clearance (Wobble Method)

If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/guide clearance with the wobble method, as indicated below.

•

Insert a new valve [A] into the guide [B] from the top of the head.

•

Set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head upper surface.

•

Move the stem back and forth [C] to measure valve/guide clearance.

•

Repeat the measurement in a direction at a right angle to the first.

If the reading exceeds the service limit, replace the guide.

NOTE

○

The reading is not actual valve/guide clearance because the measuring point is above the guide.

Valve/Guide Clearance (Wobble Method)

Standard:

Inlet

Exhaust

0.06

∼

0.13 mm (0.0024

∼

0.0051 in.)

0.10

∼

0.17 mm (0.0039

∼

0.0067 in.)

Service Limit:

Inlet

Exhaust

0.29 mm (0.011 in.)

0.33 mm (0.013 in.)


Exhaust Pipe and Muffler

Exhaust Pipe Removal

•

Remove:


Exhaust Pipe Clamp Nuts [A]

•

Remove:

Exhaust Pipe Clamp Bolts and Nuts [A]

Exhaust Pipe [B]

Muffler Removal

•

Remove:

Muffler Clamp Bolts and Nuts [A]

•

Remove:

Muffler Mounting Bolts [A]

Muffler [B]




Exhaust Pipe and Muffler

Exhaust Pipe and Muffler Installation

•

Replace the exhaust pipe gaskets [A] with new ones.

•

Tighten:

Torque - Muffler Mounting Bolts [B]: 31 N·m (3.2 kgf·m, 23 ft·lb)

Muffler Clamp Nuts [C]: 31 N·m (3.2 kgf·m, 23 ft·lb)

Exhaust Pipe Clamp Nuts [D]: 20 N·m (2.0 kgf·m,

14 ft·lb)

•

After installation, thoroughly warm up the engine, wait until the engine cools down, and then retighten the clamp nuts and muffler mounting bolts.

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 clamp.

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 clamp.

•

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 5-1



Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Air Cleaner..............................................................................................................................

Air Cleaner Element Removal...........................................................................................

Air Cleaner Element Cleaning/Inspection .........................................................................

Air Cleaner Housing Removal...........................................................................................

Torque Converter....................................................................................................................

Torque Converter Removal ...............................................................................................

Torque Converter Installation ............................................................................................

Torque Converter Case Removal......................................................................................

Torque Converter Case Installation...................................................................................

Drive Belt ................................................................................................................................

Drive Belt Removal ...........................................................................................................

Drive Belt Installation ........................................................................................................

Drive Belt Inspection .........................................................................................................

Drive Belt Deflection Inspection ........................................................................................

Drive Belt Deflection Adjustment ......................................................................................

Drive Pulley ............................................................................................................................

Drive Pulley Removal........................................................................................................

Drive Pulley Disassembly .................................................................................................

Drive Pulley Inspection .....................................................................................................

Spider Shoe Side Clearance Adjustment..........................................................................

Bushing Installation...........................................................................................................

Drive Pulley Assembly ......................................................................................................

Drive Pulley Installation.....................................................................................................

Driven Pulley ..........................................................................................................................

Driven Pulley Removal......................................................................................................

Driven Pulley Disassembly ...............................................................................................

Driven Pulley Inspection ...................................................................................................

Converter Driven Pulley Shoe Inspection .........................................................................

Bushing Installation...........................................................................................................

Driven Pulley Assembly ....................................................................................................

Driven Pulley Installation...................................................................................................

5-16

5-17

5-17

5-17

5-18

5-19

5-14

5-16

5-16

5-16

5-16

5-16

5-8

5-8

5-9

5-9

5-10

5-13

5-2

5-6

5-7

5-8

5-8

5-21

5-21

5-22

5-23

5-23

5-23

5-25

5-25

5-26

5-26

5-27

5


5-2 CONVERTER SYSTEM

Exploded View


Exploded View

No.

Fastener

1 Drive Pulley Bolt

2 Drive Pulley Cover Bolts

3 Spider

4 Weight Pin Nuts

5 Driven Pulley Bolt

6 Deflection Bolts

7 Driven Wear Shoe Screws




N·m

94

23

275

7.0

94

9.0

1.1

Torque kgf·m

9.6

2.3

28

0.70

9.6

0.92

0.11

ft·lb

69

17

203

61 in·lb

69

80 in·lb

9.7 in·lb

Remarks

R

L



Exploded View



Exploded View

No.

Fastener

1 Converter Cover Bolts

2 Converter Case Front Bolts (26.5 mm)

3 Converter Case Rear Bolts (25 mm)

4 Converter Case Cover Screws

5 Bracket Bolts

6 Air Filter Housing Bolts

G: Apply grease.

N·m

4.4

20

20

5.0

8.8

20

Torque kgf·m

0.45

2.0

2.0

0.5

0.90

2.0

ft·lb

39 in·lb

14

14

44 in·lb

78 in·lb

14

Remarks



Specifications

Item Standard

Drive Belt

Belt Deflection

Belt Width

22

∼

32 mm

(0.87

∼

1.26 in.)

26.1

∼

27.3 mm

(1.03

∼

1.07 in.)

Drive Pulley

Cover Bushing Inside Diameter

Sheave Bushing Inside Diameter

Spring Free Length

Shoe Side Clearance

28.005

∼

28.089 mm

(1.103

∼

1.106 in.)

35.002

∼

35.087 mm

(1.378

∼

1.381 in.)

72 mm (2.83 in.)

0.05

∼

0.20 mm

(0.0020

∼

0.0079 in.)

Driven Pulley

Movable Sheave Bushing Inside Diameter 38.016

∼

38.100 mm

(1.497

∼

1.500 in.)

Spring Free Length

Wear Shoe Width

105 mm (4.13 in.)

– – –

Service Limit

22

∼

50 mm (0.87

∼

1.97 in.)

25.2 mm (0.99 in.)

28.3 mm (1.114 in.)

35.3 mm (1.390 in.)

– – –

– – –

38.3 mm (1.51 in.)

– – –

1.9 mm (0.075 in.)


Special Tools

Outside Circlip Pliers:

57001-144

Bearing Driver Set:

57001-1129

Flywheel & Pulley Holder:

57001-1343

Drive Pulley Puller Bolt:

57001-1429

Pulley Holder Attachment:

57001-1472


Drive Pulley Holder:

57001-1620

Drive Pulley Wrench:

57001-1627

Drive Pulley Holder:

57001-1628

Driven Pulley Holder:

57001-1630



Air Cleaner

Air Cleaner Element Removal

•

Remove:


Wingbolts [A]

Cap [B]

•

Remove:

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.

CAUTION

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 System in the Periodic Maintenance chapter.

Air Cleaner Housing Removal

•

Remove:


Air Duct [A]

Air Cleaner Housing Bolts [B]

Air Cleaner Housing [C]

•

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.

CAUTION

If dirt gets into the torque converter, excessive wear and loss of driving power may result.


Torque Converter

Torque Converter Removal

•

Remove:

Right Rear Wheel (see Wheels/Tires chapter)

Right Rear Shock Absorber (see Suspension chapter)


Cover Bolts [A]

Torque Converter Cover [B] and Duct [C]


•

Remove the two bolts [A], holding the drive pulley bolt [B] with a wrench.

○

Be sure to remove the two bolts [A] in the positions shown.

Note the two bolts are not relative position the arrow mark

[C].

•

Install the drive pulley holder [A].

Special Tool - Drive Pulley Holder: 57001-1620

•

Tighten the two bolts [B].

Torque - Drive Pulley Cover Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)

CAUTION

Be sure to install two bolts in the specified positions shown. Otherwise, the tapped holes will be damaged.

•

Loosen the drive pulley bolt [C], holding the drive pulley with the drive pulley holder as shown.

•

Remove:

Drive Pulley Bolt

Two Washers

Stepped Washer

•

Remove the drive pulley [A] from the crankshaft by screwing the drive pulley puller bolt [B] clockwise, while holding the drive pulley with the drive pulley holder [C] as shown.

Special Tool - Drive Pulley Puller Bolt: 57001-1429




NOTE

○

Before removing the drive belt, observe the direction the belt’s printed information [A] (such as numbers, manufacture’s name or arrow marks) is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed.

•

Remove:

Drive Pulley and Drive Belt

•

Using the flywheel & pulley holder [A] and attachments

[B], remove the driven pulley bolt [C] and washers.

Special Tools - Flywheel & Pulley Holder: 57001-1343

Pulley Holder Attachment: 57001-1472

•

Remove the driven pulley [A] from the transmission shaft by screwing the drive pulley puller bolt [B] clockwise, while holding the driven pulley with the flywheel & pulley holder

[C] as shown.

Special Tool - Drive Pulley Puller Bolt: 57001-1429

Torque Converter Installation

•

Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone.

WARNING

These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.

Driven Pulley

Transmission Shaft Tapered Portion [A]

Movable Sheave Tapered Portion [B]



Drive Pulley

Crankshaft Tapered Portion [A]

Fixed Sheave Tapered Portion [B]

•

Install:

Driven Pulley

Two Washers [A] (as shown)

Transmission Case Side [B]

Bolt Head Side [C]

•

Using the flywheel & pulley holder [A] and attachments

[B], tighten the driven pulley bolt [C].

Special Tools - Flywheel & Pulley Holder: 57001-1343

Pulley Holder Attachment: 57001-1472

Torque - Driven Pulley Bolt: 94 N·m (9.6 kgf·m, 69 ft·lb)

CAUTION

Do not use the impact wrench when tightening the driven pulley bolt.

•

Install:

Drive Pulley [A] and Belt [B]

NOTE

○

Be sure the printed information [C] faces the same direction so the belt may rotate in the same direction as originally installed. When installing a new belt, install it so the printing can be read from outside the vehicle.

•

Replace the drive pulley bolt [A] with a new one.

•

Install the two washers [B] and stepped washer [C] on the drive pulley bolt as shown.





•

Install the drive pulley holder [A] (see Torque Converter

Removal).


•

Tighten the drive pulley bolt [B], holding the drive pulley with the drive pulley holder as shown.

Torque - Drive Pulley Bolt: 94 N·m (9.6 kgf·m, 69 ft·lb)

CAUTION

Do not use the impact wrench when tightening the drive pulley bolt.

•

Remove the drive pulley holder.

•

Tighten the two bolts [A], holding the drive pulley bolt [B] with a wrench.




•

Set the slit [A] of duct to aligning mark [B].

•

Install:

Torque Converter Cover [C]

Duct [D]

Collar [E]

Cover Bolts [F] (9)


Torque Converter Case Removal

•

Remove:

Drive Pulley, Driven Pulley and Drive Belt (see Torque

Converter Removal)

Converter Case Front Bolts [A] and O-rings

Converter Case Rear Bolts [B] and Washers

Dampers and Collars

Torque Converter Case [C]




Torque Converter Case Installation

•

Install:

O-rings [A]

Collars [B]



•

Set the trim seal juncture [A] in this area [B] when insert the trim seal [C] in the torque converter case [D].

[B] 40 mm (1.57 in.)

•

Install:

Torque Converter Case

Converter Case Front Bolts (26.5 mm, 1.04 in.) [E]

O-rings [F]

Collars [G]

Dampers [H]

Washers [I]

Converter Case Rear Bolts (25 mm, 0.98 in.) [J]

Converter Case Cover [K]

Screws [L]

•

Tighten:

Torque - Converter Case Front Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb)

Converter Case Rear Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb)

Converter Case Cover Screws: 5.0 N·m (0.5 kgf·m,

44 in·lb)




Drive Belt

Drive Belt Removal

•

Refer to the Torque Converter Removal.

Drive Belt Installation

•

Refer to the Torque Converter Installation.

Drive Belt Inspection

•


Drive Belt Deflection Inspection

•


Drive Belt Deflection Adjustment

•



Drive Pulley

Drive Pulley Removal

•


Drive Pulley Disassembly

•

Remove:

Drive Pulley (see Torque Converter Removal)

•

Hold the drive pulley holder [A] in a vise.


•

Set the pulley onto the pulley holder.

•

Remove:

Drive Pulley Cover Bolts [A]

Drive Pulley Cover [B]


•

Remove:

Spring [A]

Spacer

•

Put the drive pulley wrench [A] on the spider [B].

Special Tool - Drive Pulley Wrench: 57001-1627

•

Turn the wrench counterclockwise and remove the spider with the movable sheave.



Drive Pulley

•

Remove:

Spider [A]

Shoes [B]

Nuts [C]

Ramp Weight Pin [D]

Ramp Weight [E]

Movable Sheave [F]

Fixed Sheave [G]

Drive 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 cover bushing is damaged or worn, replace the drive pulley cover.

Cover Bushing Inside Diameter [A]


∼

28.089 mm (1.103

∼

1.106 in.)


If the sheave bushing is damaged or worn, replace it.

Sheave Bushing Inside Diameter [A]


∼

35.087 mm (1.378

∼

1.381 in.)



Drive Pulley

If the spider shoes [A] are damaged, replace them.

•

Check the spider shoe side clearance (see Spider Shoe

Side Clearance Inspection).


If the ramp weights [A] are damaged or worn, replace them.

If the pins [B] are damaged or worn, replace them.

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 worn or damaged, replace the spring.

Spring Free Length [A]


Spider Shoe Side Clearance Adjustment

•

Remove:

Drive Pulley (see Torque Converter Removal)

Drive Pulley Cover and Spring (see Drive Pulley Disassembly)

•

Set the drive pulley [A] without the spring onto the pulley holder [B] (see Drive Pulley Disassembly).


Temporarily install:

Dowel Pins (2)

Drive Pulley Cover

Two Bolts (at dowel pins)



Drive Pulley

•

Turn the movable sheave clockwise.

•

Measure the resulting clearance [A] between the shoe [B] and the post [C] on the movable sheave at two points as shown.

[D] Arrow Mark

Shoe Side Clearance

Standard: 0.05

∼

0.20 mm (0.0020

∼

0.0079 in.)

The clearance is not within the specified range, replace all shoes with standard shoes (P/No. 49048-1090) (see

Drive Pulley Disassembly).

•

Tighten the spider lightly by hand.

•

Turn the movable sheave clockwise.

•

Measure the resulting clearance [A] between the shoe [B] and the post [C] on the movable sheave at two positions as shown.

[D] Arrow Mark

If the clearance is not within the specified range, adjust it according to following chart.

Clearance Measurement

Present Shoes

Part Number Thickness up to 0.05 mm (0.0020 in.)

49048-1087

7.2 mm

(0.283 in.)

7.3 mm

49048-1088

(0.287 in.)

7.4 mm

49048-1089

(0.291 in.) no change over 0.05 to 0.20 mm

(over 0.0020 to 0.0079 in.) 49048-1090

(standard clearance)

7.5 mm

(0.295 in.) over 0.20 mm (0.0079 in.)

49048-1091

49048-1092

49048-1093

49048-1094

49048-1095

7.6 mm

(0.299 in.)

7.7 mm

(0.303 in.)

7.8 mm

(0.307 in.)

7.9 mm

(0.311 in.)

8.0 mm

(0.315 in.)


Drive Pulley

•

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.


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.


Drive Pulley Assembly

•

Install the ramp weights [A] as shown.

•

Tighten:

Torque - Weight Pin Nuts [B]: 7.0 N·m (0.70 kgf·m, 61 in·lb)

•

Check that the ramp weights swing smoothly.

•

Hold the fixed sheave [A] with the drive pulley holder [B] in a vise.

Special Tool - Drive Pulley Holder : 57001-1628



Drive Pulley

•

Clean the threads of the fixed sheave and spider.

•

Install:

Movable Sheave

Spider [A] and Wear 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].

Special Tool - Drive Pulley Wrench: 57001-1627

•

Turn the wrench for tightening.

Torque - Spider: 275 N·m (28 kgf·m, 203 ft·lb)

•

Put the spring [A] in the groove of the spider.

•

Align the arrows [B] on the drive pulley cover and spider.

•

Install:

Drive Pulley Cover [C]

•

Tighten:


•

Clean the surface of the sheaves with an oil-less cleaning fluid.

Drive Pulley Installation

•



Driven Pulley

Driven Pulley Removal

•


Driven Pulley Disassembly

•

Hold the driven pulley holder [A] with a suitable C clamps

[B] as shown.

Special Tool - Driven Pulley Holder: 57001-1630


•

Put the driven pulley [A] and spring holder [B] on the holder.

•

Tighten the nut [C], and compress the spring with the spring holder.

•

Remove the circlip [A] with circlip pliers [B].

Special Tool - Outside Circlip Pliers: 57001-144

•

Remove:

Nut [A]

Spring Holder [B]

Circlip [C]



Driven Pulley

•

Remove:

Ramp [A]

Spring [B]

Movable Sheave [C]

Spacer [D]

Fixed Sheave [E]

If the ramp [A] does not come off easily, face the ramp downward and tap it lightly.

•

Remove:

Screws [A]

Wear Shoes [B]

Bolts [C]

Shims [D]


Driven Pulley

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


∼

38.100 mm (1.497

∼

1.500 in.)


If the splines [A] of the fixed sheave [B] and ramp [C] are damaged or worn, replace them.

If the spring is damaged or worn, replace the spring.

Spring Free Length [A]

Standard: 105 mm (4.13 in.)

Converter Driven Pulley Shoe Inspection

•

Refer to the Converter System in the Periodic Maintenance Chapter.



Driven Pulley

Bushing Installation

•

Press the movable sheave bushings [A] into the movable sheave [B] using the special tool so that the end of bushing are flush with the shoulder [C] in the holes.


Driven Pulley Assembly

•

Install the wear shoes [A] on the movable sheave as follows.

○

The wear shoe must be installed so that the grooves [B] on the shoe faces inside.

•

Apply a non-permanent locking agent to the wear shoe mounting screws [C].

•

Tighten:

Torque - Driven Wear Shoe Mounting Screws: 1.1 N·m (0.11

kgf·m, 9.7 in·lb)

•

Hold the fixed sheave with the driven pulley holder.


•

Install the spacer [A] on the fixed sheave [B].

•

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 “2” on the ramp.

•

Align the flat portions [C] of spline on the fixed sheave and ramp.


Driven Pulley

•

Put the circlip [A] on the ramp.

•

Install the spring holder [B].

•

Push down the ramp halfway by tightening the nut [C].


•

Turn the movable sheave [A] counterclockwise 120° with the driven pulley holder [B].


•

Tighten the holder bolts [A], and hold the movable sheave

[B].

•

Tighten the nut [A] until the groove of the circlip is seen.

•

Install the circlip [B].


•

Release the movable sheave slowly until it stops naturally.

Driven Pulley Installation

•




ENGINE LUBRICATION SYSTEM 6-1



Exploded View........................................................................................................................

Specifications .........................................................................................................................

Engine Oil Flow Chart.............................................................................................................

Engine Oil and Oil Filter..........................................................................................................

Oil Level Inspection...........................................................................................................

Engine Oil Change............................................................................................................

Oil Filter Replacement ......................................................................................................

Oil Pump, Relief Valve............................................................................................................

Oil Pump Removal ............................................................................................................

Oil Pump Installation .........................................................................................................

Oil Pump Inspection..........................................................................................................

Relief Valve Removal........................................................................................................

Relief Valve Installation.....................................................................................................

Relief Valve Inspection......................................................................................................

Oil Screen...............................................................................................................................

Oil Screen Removal ..........................................................................................................

Oil Screen Installation .......................................................................................................

Oil Screen Cleaning/Inspection.........................................................................................

Oil Temperature Sensor (KAF400-A/C) ..................................................................................

Oil Temperature Sensor Removal.....................................................................................

Oil Temperature Sensor Installation..................................................................................

6-7

6-7

6-8

6-8

6-8

6-8

6-2

6-4

6-5

6-6

6-6

6-9

6-10

6-10

6-11

6-11

6-11

6-11

6-12

6-12

6-12

6


6-2 ENGINE LUBRICATION SYSTEM

Exploded View



Exploded View

No.

Fastener

1 Oil Line Plugs

2 Oil Filter

3 Oil Filter Joint

4 Joint (KAF400-A/C)

5 Oil Temperature Sensor (KAF400-A/C)

6 Engine Oil Drain Plugs

7 Oil Plug


G: Apply grease.

L: Apply a non-permanent locking agent to the threads.


N·m

3.9

9.8

6.9

7.4

5.5

6.9

6.9

Torque kgf·m

0.40

1.0

0.70

0.75

0.56

0.70

0.70

ft·lb

34 in·lb

87 in·lb

61 in·lb

65 in·lb

49 in·lb

61 in·lb

61 in·lb

Remarks

L



Specifications

Item

Engine Oil and Oil Filter

Engine Oil:

Grade

Standard Service Limit

Viscosity

Capacity

Oil Level

Oil Pump and Relief Valve

Inner Rotor/Outer Rotor

Clearance

API SF or SG

API SH or SJ with JASO MA

SAE10W-40

– – –

– – –

1.1 L (1.16 US qt) (when filter is not removed) – – –

1.3 L (1.37 US qt) (when filter is removed) – – –

Between L and H lines on dipstick – – –

Less than 0.14 mm (0.006 in.) 0.20 mm (0.0079 in.)

40.53

∼

40.56 mm (1.5957

∼

1.5968 in.) 40.47 mm (1.5933 in.) Outer Rotor Outside

Diameter

Outer Rotor Thickness

Pump Housing Inside

Diameter

9.98

∼

10.00 mm (0.3929

∼

0.3937 in.) 9.94 mm (0.3913 in.)

40.680

∼

40.701 mm (1.6016

∼

1.6024 in.) 40.801 mm (1.6063 in.)

10.03

∼

10.08 mm (0.3949

∼

0.3968 in.) 10.16 mm (0.4000 in.)

12.695

∼

12.715 mm (0.4998

∼

0.5006 in.) 12.645 mm (0.4978 in.)

Pump Housing Depth

Pump Shaft Outside

Diameter

Pump Shaft Bearing

Inside Diameter

Relief Valve Spring Free

Length

12.735

∼

12.750 mm (0.5014

16.5 mm (0.6496 in.)

∼

0.5020 in.) 12.811 mm (0.5044 in.)

15.7 mm (0.618 in.)


Engine Oil Flow Chart


1. Oil Pump

2. Rocker Arms

3. Oil Filter

4. Camshaft

5. Relief Valve

6. Crankshaft

7. Oil Screen




WARNING

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury.

Oil Level Inspection

NOTE

○

If the vehicle has just been used, wait several minutes for all the oil to drain down.

○

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.

CAUTION

Racing the engine before the oil reaches every part can cause engine seizure.

•

Park the vehicle on level ground, and tilt up the seat.

•

Remove:

Cap

•

Pull out the oil level gauge [A] and wipe it dry.

•

Apply engine oil to the rubber seal lip [A] on the dipstick.

•

Insert the oil level gauge into the oil filler hole securely.

CAUTION

Always insert the oil level gauge into the oil filler hole so that the taper part [A] of the cap is facing rearwards.




•

Pull out the oil level gauge and check the oil level. The oil level should be between the “H”(High) and “L”(Low) lines

[A] on the dipstick.

If the oil level is too high, remove the excess oil, using a syringe or some other suitable device, or removing the engine oil drain plug, drain the excess oil.

If the oil level is too low, add the correct amount of oil through the oil filler hole. Use the same type and make of oil that is already in the engine.

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.

•

Install the oil level gauge securely.

Engine Oil Change

•

Refer to the Engine Oil Change section in the Periodic


Oil Filter Replacement

•

Refer to the Oil Filter Replacement section in the Periodic




Oil Pump, Relief Valve

Oil Pump Removal

•

Remove the crankcase cover (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter).

•

Remove the circlip [A] and oil pump assembly (pump cover plate, inner rotor, outer rotor).

Oil Pump Installation

•

Fill the rotor housing with engine oil for initial lubrication.

•

Install the pump assembly and circlip in the crankcase cover.

○

Install the circlip [A] with the tapered side out [B], as shown in figure.

Oil Pump Inspection

•

Remove the oil pump (see Oil Pump Removal in this chapter).

•

Visually inspect the pump gear, outer and inner rotor, and cover plate.

If there is any damage or uneven wear, replace them.

○

Check the clearance [A] between the inner and outer rotor with a feeler gauge. Measure the clearance between the high point of the inner rotor and the high point of the outer rotor.

If the measurement exceed the service limit, replace the rotors as a set.

Inner and Outer Rotor Clearance

Standard: Less than 0.14 mm (0.006 in.)


•

Measure the outside diameter [A] of the outer rotor with a micrometer at several points.

If the rotor diameter is less than the service limit, replace both the inner and outer rotor.

Outer Rotor Outside Diameter

Standard: 40.53

∼

40.56 mm (1.5957

∼

1.5968 in.)


•

Measure the thickness [B] of the outer rotor with a micrometer at several points.

If the rotor thickness is less than the service limit, replace both the inner and outer rotor.

Outer Rotor Thickness

Standard: 9.98

∼

10.00 mm (0.3929

∼

0.3937 in.)





•

Measure the inside diameter [A] of the pump housing with an inside micrometer at several points.

If the inside diameter is more than the service limit, replace the crankcase cover.

Pump Housing Inside Diameter


∼

40.701 mm (1.6016

∼

1.6024 in.)


•

Measure the depth [B] of the pump housing with a depth micrometer at several points.

If any of measurement is more than the service limit, replace the crankcase cover.

Pump Housing Depth

Standard: 10.03

∼

10.08 mm (0.3949

∼

0.3968 in.)


•

Measure the outside [A] diameter of the pump shaft with a micrometer at several points.

If the diameter is less than the service limit, replace the pump shaft.

Pump Shaft Outside Diameter


∼

12.715 mm (0.4998

∼

0.5006 in.)


•

Measurer the inside diameter [A] of the pump shaft bearing in the crankcase cover with a inside micrometer at several points.

If the inside diameter is more than the service limit replace the crankcase cover.

Pump Shaft Bearing Inside Diameter


∼

12.750 mm (0.5014

∼

0.5020 in.)


Relief Valve Removal

•

Remove:

Camshaft (see Camshaft, Tappet Removal in the Engine

Bottom End chapter)

Relief Valve Cover Bolt [A]

Relief Valve Cover [B]




Relief Valve Installation

•

Install:

Relief Valve Ball [A]

Spring [B]

Relief Valve Cover

Relief Valve Cover Bolt

Relief Valve Inspection

•

Visually inspect the relief valve spring, steel ball and valve seat in the crankcase.

If any rough spots are found during above inspection, wash the valve clean with a high flash-point solvent and blow out any foreign particles that may be in the valve with compressed air.

WARNING

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

-point solvents.

If cleaning does not solve the problem, replace the relief valve parts.

If necessary, put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat.

•

Measure free length [A] of the spring with a vernier caliper.

If the free length of the spring is less than the service limit, replace the spring.

Relief Valve Spring Free Length

Standard: 16.5 mm (0.6496 in.)




Oil Screen

Oil Screen Removal

•

Remove:

Engine

Crankcase Cover (see Engine Bottom End chapter)

Oil Screen Bolts [A]

Pipe [B]

•

Push [C] the oil screen with thumbs and remove it.

Oil Screen Installation

•

Clean the oil screen thoroughly whenever it is removed for any reason.

•

Insert the oil screen [A] into slots [B] in the pipe [C], and install the pipe on the crankcase cover with the mounting bolts and spacers.

Oil Screen Cleaning/Inspection

•

Clean the oil screen [A] with high flash-point solvent and remove any particles stuck to it.

WARNING

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

-point solvents.

NOTE

○

While cleaning the screen, check for any metal particles that might indicate internal engine damage.

•

Check the screen carefully for any damage: holes and broken wire.

If the screen is damaged, replace it.



Oil Temperature Sensor (KAF400-A/C)

Oil Temperature Sensor Removal

•

Remove:

Engine oil (drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Sensor Lead Connector

Oil Temperature Sensor [A]

Oil Temperature Sensor Installation

•

Apply engine oil to the O-ring on the sensor.

•

Tighten:

Torque - Oil Temperature Sensor [A]: 5.5 N·m (0.56 kgf·m,

49 in·lb)

Joint [B]: 7.4 N·m (0.75 kgf·m, 65 in·lb)


ENGINE REMOVAL/INSTALLATION 7-1



Exploded View........................................................................................................................

Special Tool ............................................................................................................................

Engine Removal/Installation ...................................................................................................

Engine Removal................................................................................................................

Engine Installation.............................................................................................................

7-2

7-4

7-5

7-5

7-6

7


7-2 ENGINE REMOVAL/INSTALLATION

Exploded View


Exploded View

No.

Fastener

1 Engine Mounting Bolts and Nuts

2 Connecting Plate Bolts (M8)




N·m

24.5

28

55

Torque kgf·m

2.5

2.9

5.6

ft·lb

18

21

41

Remarks

L

L



Special Tool

Alignment Jig:

57001-1631




Engine Removal

•

Disconnect:

Battery Terminal Leads (see Electrical System chapter)

•

Remove:

Cargo Bed


Exhaust Pipe (see Engine Top End chapter)

Torque Converter Case (see Converter System chapter)

Connecting Plate (see Transmission Case in the Transmission chapter)


Link Bracket [A]

Starter Motor Lead [B] and Connector [C]

Alternator Lead Connector [D]

Ignition Coil Lead Connector [E]

Oil Temperature Sensor Lead Connector [F]

Hose [G]

•

Remove:

Engine Mounting Bolts [A] (both sides)

Engine Ground Lead [B]

•

Remove:

Engine [A]




Engine Installation

If the transmission case has not been removed, start from the step 2.

Step 1

•

Mount the transmission case [A] with the rear axle brackets [B] on the swingarm.

•

Tighten the rear axle bracket bolts [C] lightly by hand.

Step 2

•

Mount the engine [D] on the swingarm.

•

Install the engine mount bolts and tighten the nuts [E] lightly by hand.

•

Install the connecting plate [F] to the engine and transmission case so that the plate fits to the face shown by spigot joint areas [G].

•


Connecting Plate Bolts (M10) [H]

Connecting Plate Bolts (M8) [I]

•

Install the washers and tighten the connecting plate bolts

(M10 and M8) lightly by hand.

•

Install the alignment jig [J] and tighten the bolts.

Special Tool - Alignment Jig: 57001-1631

•

Tighten the bolts in the following order.

Torque - Connecting Plate Bolts (M10): 55 N·m (5.6 kgf·m,

41 ft·lb)

Connecting Plate Bolts (M8): 28 N·m (2.9 kgf·m,

21 ft·lb)

Engine Mounting Bolts and Nuts: 24.5 N·m (2.5

kgf·m, 18 ft·lb)

Rear Axle Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

•

Remove the alignment jig.






ENGINE BOTTOM END 8-1



Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Crankcase Cover....................................................................................................................

Crankcase Cover Removal ...............................................................................................

Crankcase Cover Assembly..............................................................................................

Crankcase Cover Installation ............................................................................................

Camshaft and Tappets............................................................................................................

Camshaft, Tappet Removal...............................................................................................

Camshaft, Tappet Installation............................................................................................

Camshaft Disassembly .....................................................................................................

Camshaft Assembly ..........................................................................................................

Camshaft Inspection .........................................................................................................

Camshaft Bearing/Journal Wear.......................................................................................

Cylinders and Pistons.............................................................................................................

Piston Removal.................................................................................................................

Piston Installation..............................................................................................................

Piston Cleaning.................................................................................................................

Piston Ring and Ring Groove Wear..................................................................................

Piston Ring End Gap ........................................................................................................

Piston Pin, Piston Pin Hole, and Connecting Rod Wear...................................................

Piston Diameter ................................................................................................................

Cylinder Inside Diameter...................................................................................................

Crankshaft and Connecting Rods...........................................................................................

Connecting Rod Removal .................................................................................................

Connecting Rod Installation ..............................................................................................

Crankshaft Removal .........................................................................................................

Crankshaft Installation ......................................................................................................

Cleaning/Inspection .........................................................................................................

Connecting Rod Bend/Twist..............................................................................................

Connecting Rod Big End/Crankpin Width Wear ...............................................................

Connecting Rod Big End Bearing/Crankpin Wear ............................................................

Crankshaft Runout ............................................................................................................

Crankshaft Main Bearing/Journal Wear ............................................................................

Balancer Shaft ........................................................................................................................

Balancer Shaft Removal ...................................................................................................

Balancer Shaft Installation ................................................................................................

Balancer Shaft Bearing/Journal Wear...............................................................................

Breather..................................................................................................................................

Breather Valve Removal ...................................................................................................

Breather Valve Installation ................................................................................................

Breather Valve Inspection .................................................................................................

8-17

8-17

8-17

8-17

8-17

8-17

8-18

8-18

8-11

8-12

8-13

8-14

8-15

8-15

8-16

8-16

8-8

8-8

8-8

8-9

8-9

8-9

8-10

8-11

8-2

8-4

8-6

8-7

8-7

8-7

8-7

8-19

8-19

8-19

8-21

8-21

8-21

8-21

8-22

8-23

8-23

8-23

8


8-2 ENGINE BOTTOM END

Exploded View



Exploded View

No.

Fastener

1 Connecting Rod Big End Cap Bolts

2 Breather Valve Screw

3 Oil Filter Joint

4 Oil Line Plugs

5 Crankcase Cover Bolts

6 Engine Oil Drain Plugs


G: Apply grease.




S: Follow the specific tightening sequence.

N·m

5.9

3.4

6.9

3.9

21.6

6.9

Torque kgf·m

0.60

0.35

0.70

0.40

2.2

0.70

ft·lb

52 in·lb

30 in·lb

61 in·lb

34 in·lb

16

61 in·lb

Remarks

EO

L

S



Specifications

Item

Camshaft and Tappets

Cam Lobe Height:

Inlet

Standard Service Limit

Exhaust

29.955

∼

30.045 mm

(1.179

∼

1.183 in.)

29.955

∼

30.045 mm

(1.179

∼

1.183 in.)

29.86 mm (1.176 in.)

29.86 mm (1.176 in.)

Camshaft Journal Diameter:

Crankcase Side

Crankcase Cover Side

19.967

∼

19.980 mm

(0.7861

∼

0.7866 in.)

49.959

∼

49.975 mm

(1.9669

∼

1.9675 in.)

19.94 mm (0.785 in.)

49.93 mm (1.966 in.)

Camshaft Bearing Inside Diameter:

Crankcase Side


20.000

∼

20.013 mm

(0.7874

∼

0.7879 in.)

50.000

∼

50.025 mm

(1.9685

∼

1.9695 in.)

20.07 mm (0.790 in.)

50.09 mm (1.972 in.)

Cylinders and Pistons

Piston Ring/Groove Clearance:

Top, Second 0.04

∼

0.08 mm

(0.0016

∼

0.0031 in.)

0.18 mm (0.0071 in.)

Piston Ring Thickness:

Top, Second 1.47

∼

1.49 mm

(0.0579

∼

0.0587 in.)

1.40 mm (0.0551 in.)

Piston Ring End Gap:

Top

Second

Oil

Piston Pin Outside Diameter

Piston Pin Hole Inside Diameter

Connecting Rod Small End Inside

Diameter

Piston Diameter

Cylinder Inside Diameter

Cylinder Bore Out-Round

Piston/Cylinder Clearance

0.15

∼

0.40 mm

(0.0059

∼

0.0157 in.)

0.23

∼

0.48 mm

(0.0091

∼

0.0189 in.)

0.25

∼

0.75 mm

(0.0098

∼

0.0295 in.)

18.995

∼

19.000 mm

(0.7478

∼

0.7480 in.)

19.004

∼

19.015 mm

(0.7482

∼

0.7486 in.)

19.010

∼

19.021 mm

(0.7484

∼

0.7489 in.)

81.935

∼

81.955 mm

(3.2258

∼

3.2266 in.)

81.97

∼

81.99 mm

(3.2272

∼

3.2279 in.)

– – –

0.015

∼

0.055 mm

(0.0006

∼

0.0022 in.)

0.7 mm (0.028 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

18.96 mm (0.746 in.)

19.08 mm (0.751 in.)

19.06 mm (0.750 in.)

81.79 mm (3.220 in.)

82.10 mm (3.232 in.)

0.05 mm (0.0020 in.)

– – –

Crankshaft and Connecting Rods

Connecting Rod Bend – – – 0.2/100 mm

(0.008/3.937 in.)

Connecting Rod Twist – – – 0.2/100 mm



Specifications

Item Standard

Connecting Rod Big End Width

Crankpin Width

27.4

∼

27.7 mm

(1.079

∼

1.091 in.)

28.0

∼

28.2 mm

(1.102

∼

1.110 in.)

Connecting Rod Big End Inside Diameter 43.004

∼

43.015 mm

(1.6931

∼

1.6935 in.)

Crankpin Outside Diameter 42.957

∼

42.970 mm

(1.6912

∼

1.6917 in.)

Crankshaft Runout TIR 0.02 mm

(0.0008 in.) or less

Crankshaft Main Journal Diameter

Crankcase Side 34.955

∼

34.980 mm

(1.3762

∼

1.3772 in.)

Crankshaft Main Bearing Inside Diameter

Crankcase Side 35.002

∼

35.015 mm

(1.3780

∼

1.3785 in.)

Balancer Shaft

Balancer Shaft Journal Diameter 31.959

∼

31.975 mm

(1.2582

∼

1.2589 in.)

Balancer Shaft Bearing Inside Diameter:

Crankcase Side


32.000

∼

32.016 mm

(1.2598

∼

1.2605 in.)

32.000

∼

32.016 mm

(1.2598

∼

1.2605 in.)

Service Limit

27.0 mm

(1.063 in.)

28.4 mm

(1.112 in.)

43.04 mm

(1.694 in.)

42.94 mm

(1.691 in.)

TIR 0.05 mm

(0.002 in.)

34.93 mm

(1.375 in.)

35.05 mm

(1.380 in.)

31.935 mm

(1.257 in.)

32.06 mm

(1.262 in.)

32.06 mm

(1.262 in.)



Special Tools

Piston Ring Compressor Grip:

57001-1095


57001-1129

Piston Ring Compressor Belt, 80

∼

91:

57001-1320


Crankcase Cover

Crankcase Cover Removal

•

Remove:

Engine (see Engine Removal/Installation chapter)

Engine Oil (drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Crankcase Cover Bolts [A]

Crankcase Cover [B]

NOTE

○

If the crankcase cover sticks, tap lightly with a mallet near the dowel pins [C].

Crankcase Cover Assembly

•

Install the ball bearing [A] until it is bottomed.


•

Apply grease to 60% volume between seal lips.

•

Install the oil seal [B] at specified position as shown.

[C] Crankcase Cover

[D] 4.0

∼

4.5 mm (0.16

∼

0.18 in.)


Crankcase Cover Installation

•

Check to see that the dowel pins [A] are in place on the crankcase.

•

Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown.

Torque - Crankcase Cover Bolts: 21.6 N·m (2.2 kgf·m, 16 ft·lb)




Camshaft, Tappet Removal

•

Drain the oil (see Oil Change in the Periodic Maintenance chapter).

•

Remove:

Crankcase Cover (see Crankcase Cover Removal)

Cylinder Head Cover [A]

•

Position the piston TDC at the end of the compression stroke.

•

Remove the lock screws [A] and the valve clearance adjusting nuts [B] which install the rocker arm [C], and pull the rocker arm off the push rods [D].

•

Remove the push rods and mark them so they can be installed in their original positions during assembly.

•

Pull the camshaft [A] out of the crankcase.

•

Remove the tappets [A] and mark them so they can be installed in their original positions during assembly.

Camshaft, Tappet Installation

•

Apply engine oil to the following.

Tappet Journal

Camshaft Journal

Cam Lobe Surface

Camshaft Gear

•

Install the tappets in their original positions.

•

Align the punch marks [A] on the crankshaft gear and on the camshaft gear.



•

Install the crankcase cover (see Crankcase Cover Installation).

•

Install the push rods (see Push Rod Installation in the

Engine Top End chapter).

•

Mount the rocker arms on the push rods, and install the valve clearance adjusting nuts and the lock screws.

Torque - Valve Adjusting Nut Lock Screws: 6.9 N·m (0.70


•

Adjust the valve clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter).

•

Install the cylinder head cover.

Camshaft Disassembly

•

Remove:

Spring [A]

•

Do not remove the ACR (Automatic Compression Release) weight [B].


•

Camshaft Assembly

After assembling the camshaft, check the following item.

○

While shaking the camshaft, ACR weight [A] swings smoothly.

Camshaft Inspection

•

Check the camshaft gear [A] for pitting, fatigue cracks, burrs or an evidence of improper tooth contact.

Replace the shaft if necessary.

•

Check the top of the cam lobes [B] for wear, burrs or uneven contact.

Replace the shaft if necessary.

•

Inspect the camshaft to make sure that its Automatic

Compression Release (ACR) function operates smoothly and does not have any damage or abnormal wear.

If ACR parts are worn, replace the camshaft.

When the weight [A] is closed, if the top of the shaft [B] is lower than the base [C], replace the camshaft with a new one.

When the weight is pulled entirely outward with your finger, if the top of the shaft is higher than the cam base, replace the camshaft with a new one.




Camshaft Bearing/Journal Wear

•

Measure the height of each cam lobe [A].

If the cam height is less than the service limit for either lobe, replace the camshaft.

Cam Lobe Height

Standard:

Inlet

Exhaust

Service Limit:

Inlet

Exhaust

29.955

∼

30.045 mm (1.179

∼

1.183 in. )

29.955

∼

30.045 mm (1.179

∼

1.183 in. )

29.86 mm (1.176 in.)

29.86 mm (1.176 in.)

•

Measure both camshaft journals at several points around the journal circumference.

If the journal diameter is less than the service limit, replace the camshaft.

Crankcase Side Camshaft Journal Diameter

Standard 19.967

∼

19.980 mm (0.7861

∼

0.7866 in. )


Crankcase Cover Side Camshaft Journal Diameter


∼

49.975 mm (1.9669

∼

1.9675 in. )


•

Measure the inside diameter [A] of the camshaft bearing on the crankcase at several points.

Replace the crankcase if the inside diameter is more than the service limit.

Camshaft Bearing Inside Diameter (Crankcase)


∼

20.013 mm (0.7874

∼

0.7879 in. )


•

Measure the inside diameter [A] of the camshaft bearing on the crankcase cover at several points.

Replace the crankcase cover if the inside diameter is more than the service limit.

Camshaft Bearing Inside Diameter (Crankcase Cover)


∼

50.025 mm (1.9685

∼

1.9695 in. )




Piston Removal

•

Remove:


Camshaft (see Camshaft, Tappet Removal)

Balancer Shaft (see Balancer Shaft Removal)

•

Turn the crankshaft to expose the connecting rod cap bolts [A].

•

Remove the bolts and take off the connecting rod cap [B].

NOTE

○

Note the position of the connecting rod caps for reinstalling the caps.

•

Push the connecting rod end into the cylinder, and pull the piston and connecting rod out of the cylinder.

•

Remove one of the piston pin snap rings [A] with needle nose pliers.


•

Remove the piston by pushing the piston pin [A] out the side from which the snap ring was removed.

•

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

•

Install the expander [A] in the piston oil ring groove so that the expander ends [B] touch together, never overlap.

•

Install the upper and lower steel rails. There is no UP or

Down to the rails. They can be installed either way.

•

Do not mix up the top and second rings.

•

Install the second ring so that the notched edge [A] faces down.

•

Install the top ring.

•

The rings should turn freely in the grooves.

Piston Head [B]

Top Ring [C]

Second Ring [D]

•

Align the piston and rings with the piston ring end gap as shown.

Arrow Match Marks [A]

Top ring End Gap, Upper Steel Rail End Gap [B]

About 45° [C]

Second Ring End Gap, Lower Steel Rail End Gap [D]

•

Apply engine oil to the piston pins.

•

Assemble the piston onto the connecting rod so that the arrow mark [A] on the top of the piston can be aligned with

“MADE IN USA” [B] on the connecting rod.

•

Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the notch

[B] in the edge of the piston pin hole.

○

When installing a piston pin snap ring, compress it only enough to install it and no more.

CAUTION

Do not reuse the snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.



•

Apply engine oil to the piston skirt and the cylinder bore.

•

Using the piston ring compressor grip [A] and the belt [B], lightly tap the top of the piston with a plastic mallet [C] to insert the piston and connecting rod into the cylinder.

Special Tools - Piston Ring Compressor Grip: 57001-1095

Piston Ring Compressor Belt, 80

∼

91:

57001-1320

•

Facing the arrow mark [D] on the top of the piston toward the alternator rotor side [E].

CAUTION

The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set.

•

Apply engine oil to the inner surface [A] of the connecting rod big end [B] and caps [C].

•

Install the connecting rod big end caps in their original position on the connecting rod big ends by matching the marks [D].

•

Apply a small amount of engine oil to the thread and seating surface of the cap bolts [E].

•

Tighten the cap bolts.

Torque - Connecting Rod Big End Cap Bolts: 5.9 N·m (0.60


•

Install:

Camshaft (see Camshaft, Tappet Installation)

Crankcase Cover (see Crankcase Cover Installation)

Piston Cleaning

•

Remove the piston and piston rings (see Piston Removal).

CAUTION

Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings.

•

Scrape the carbon off the piston head with a scraper [A].

•

Use the scraping tools carefully. Do not gouge the piston head. To avoid gouging, use scrapers that are made of a material that will not cause damage.

•

Clean the piston ring grooves [A] with a broken piston ring or other suitable tools.

CAUTION

Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement.





Piston Ring and Ring Groove Wear

•

Clean the piston (see Piston Cleaning).

•

Visually inspect the piston rings and ring grooves.

If the piston rings are worn unevenly or damaged, replace them.

If the ring grooves are worn unevenly or damaged, replace both the piston and piston rings.

•

Measure the clearance between the top and second rings and their grooves using a thickness gauge [A].

If the piston ring/groove clearance is greater than the specified value, replace the piston.

Piston Ring/Groove Clearance

Standard:

Top, Second 0.04

∼

0.08 mm (0.0016

∼

0.0031 in.)

Service Limit:

Top, Second 0.18 mm (0.0071 in.)

NOTE

○

The oil ring is a three piece assembled ring. It is difficult to measure the ring groove clearance and thickness, visually inspect only.

•

Measure the piston ring thickness [A].

○

Use a micrometer to measure at several points around the rings.

If any of the measurement are less than the service limit, replace the entire set of rings.

Piston Ring Thickness

Standard:

Top, Second 1.47

∼

1.49 mm (0.0579

∼

0.0587 in.)

Service Limit

Top, Second 1.40 mm (0.0551 in.)

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 End Gap

•

Remove the piston rings.

•

Push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore.

○

Use the piston to push it in to be sure it is square.

•

Measure the gap [A] between the ends of the ring [B] with a thickness gauge.

If the end gap of any ring is greater than the service limit, replace the entire set of rings.

Piston Ring End Gap

Standard:

Top

Second

Oil

0.15

∼

0.40 mm (0.0059

∼

0.0157 in.)

0.23

∼

0.48 mm (0.0091

∼

0.0189 in.)

0.25

∼

0.75 mm (0.0098

∼

0.0295 in.)

Service Limit:

Top 0.7 mm (0.028 in.)

Second

Oil

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

Piston Pin, Piston Pin Hole, and Connecting Rod

Wear

•

Remove the piston pin.

•

Measure the outside diameter of the piston pin with a micrometer at several points.

If the outside diameter is less than service limit, replace the piston pin.

Piston Pin Outside Diameter


∼

19.000 mm (0.7478

∼

0.7480 in.)


•

Measure the inside diameter [A] of the piston pin hole at several points on both side. Use a dial bore gauge.

If the inside diameter is more than the service limit, replace the piston.

Piston Pin Hole Inside Diameter


∼

19.015 mm (0.7482

∼

0.7486 in.)



•

Measure the inside diameter [A] of the small end of the connecting rod at several points. Use a dial bore gauge.

If the inside diameter is more than the service limit, replace the connecting rod.

Connecting Rod Small End Inside Diameter


∼

19.021 mm (0.7484

∼

0.7489 in.)





Piston Diameter

•

Measure the outside diameter [A] of the piston 18 mm

(0.71 in.) up [B] from the bottom of the piston at a right angle to the direction of the piston pin hole.

If the measurement is less than the service limit, replace the piston.

Piston Diameter


∼

81.955 mm (3.2258

∼

3.2266 in.)


•

Cylinder Inside Diameter

Clean and measure the cylinder inside diameter.

○

Use a dial bore gauge to measure front-to-back and side

-to-side at the points as shown in the figure.

If any of the cylinder bore measurements is greater than the service limit, replace the crankcase.

10 mm (0.39 in.) [A]

35 mm (1.38 in.) [B]

Cylinder Inside Diameter

Standard: 81.97

∼

81.99 mm (3.2272

∼

3.2279 in.)


Cylinder Bore Out-Round




Connecting Rod Removal

•

Refer to the Piston Removal for the connecting rod removal.

Connecting Rod Installation

•

Refer to the Piston Installation for the connecting rod installation.

Crankshaft Removal

•

Drain the oil (see Oil Change in the Periodic Maintenance chapter).

•

Remove:

Alternator Rotor (see Alternator Rotor and Stator Removal in the Electrical System chapter)

Camshaft (see Camshaft, Tappet Removal)

Balancer shaft (see Balancer Shaft Removal)

Connecting Rod Cap (see Piston Removal)

•

Pull the crankshaft [A] out of the crankcase. Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft.

Crankshaft Installation

•

Clean up the crankshaft and crankcase thoroughly, especially at the bearing contact surfaces.

•

Pack some amount of grease to 60% volume between the lips of the oil seal on the crankcase. Press in the new oil seal 0

∼

1 mm (0

∼

0.04 in.) below the crankcase surface.

•

Apply molybdenum disulfide grease to the alternator side journal.

•

Apply engine oil to the crank pin and bearing.

•

Insert the crankshaft into the crankcase.

Cleaning/Inspection

•

After removing, clean the crankshaft and connecting rods with a high flash-point washing and dry them with compressed air.

•

Inspect the teeth of the crankshaft gear for pitting, fatigue cracks, burrs and evidence of improper tooth contact.

Replace the gear if necessary.

•

Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear, scratches, evidence of improper contact or other damages.

Replace them if necessary.





•

Connecting Rod Bend/Twist

Measure connecting rod bend.

○

Select an arbor of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end.

○

Select an arbor of the same diameter as the piston pin and at least 100 mm long, and insert the arbor through the connecting rod small end.

○

On a surface plate, set the big-end arbor on V blocks [A].

○

With the connecting rod held vertically, use a height gauge [B] to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend.

If connecting rod bend exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Bend

Service Limit: 0.2/100 mm (0.008/3.937 in.)

•

Measure connecting rod twist.

○

With the big-end arbor still on the V blocks [A], hold the connecting rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist by using a height gauge [B].

If connecting rod twist exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Twist

Service Limit: 0.2/100 mm (0.008/3.937 in.)

Connecting Rod Big End/Crankpin Width Wear

•

Measure the connecting rod big end width [A] with a micrometer or dial caliper.

If the measurement is less than the service limit, replace the connecting rod.

Connecting Rod Big End Width

Standard: 27.4

∼

27.7 mm (1.079

∼

1.091 in.)


•

Measure the crankpin width [A] with a dial caliper.

If the crankpin width is more than the service limit, replace the crankshaft.

Crankpin Width

Standard: 28.0

∼

28.2 mm (1.102

∼

1.110 in.)




Connecting Rod Big End Bearing/Crankpin Wear

•

Apply a thin film of oil on the thread of the cap bolts.

•

Install the cap bolts and tighten the bolts to the specified torque (see Piston Installation in the Engine Top End chapter).

•

Measure the inside diameter [A] of big end at several points with a telescoping gauge or inside micrometer.

If the inside diameter is more than the service limit, replace the connecting rod with a new one.

Connecting Rod Big End Inside Diameter


∼

43.015 mm (1.6931

∼

1.6935 in.)


•

Measure the crankpin outside diameter [A].

○

Use a micrometer to measure several points around the crankpin circumference.

If the crankpin diameter is less than the service limit, replace the crankshaft with a new one.

Crankpin Outside Diameter


∼

42.970 mm (1.6912

∼

1.6917 in.)



•

Crankshaft Runout

Measure the crankshaft runout.

○

Set the crankshaft in a flywheel alignment jig [A] or on V blocks gauge.

○

Set a dial gauge [B] against both bearing journals.

○

Turn the crankshaft slowly to measure the runout. The difference between the highest and lowest dial gauge readings (TIR) is the amount of runout.

If the measurement exceeds the service limit, replace the crankshaft.

Crankshaft Runout

Standard: TIR 0.02 mm (0.0008 in.) or less


Crankshaft Main Bearing/Journal Wear

•

Measure the diameter [A] of the crankshaft main journal.

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

Crankcase Side Crankshaft Main Journal Diameter


∼

34.980 mm (1.3762

∼

1.3772 in.)





•

Measure the inside diameter [A] of the crankshaft main bearing (crankcase side).

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

Crankshaft Main Bearing Inside Diameter (Crankcase

Side)

Standard 35.002

∼

35.015 mm (1.3780

∼

1.3785 in.)

Service Limit 35.05 mm (1.380 in.)


Balancer Shaft

Balancer Shaft Removal

•

Remove:


Balancer Shaft [A]


Balancer Shaft Installation

•

Install the balancer shaft to the balancer shaft bearing on the crankcase.

•

Install the crankcase cover (see Crankcase Cover Installation).

•

Align the punch marks [A] on the crankshaft gear and on the balancer shaft gear.

Balancer Shaft Bearing/Journal Wear

•

Measure both balancer shaft journals diameter [A] at several points around the journal circumference.

If journal diameter is less than the service limit, replace the balancer shaft with a new one.

Balancer Shaft Journal Diameter

Standard 31.959

∼

31.975 mm (1.2582

∼

1.2589 in.)


•

Measure the inside diameter [A] of the balancer shaft bearing on the crankcase at several points.

If inside diameter is more than the service limit, replace the crankcase with a new one.

Balancer Shaft Bearing Inside Diameter (Crankcase)

Standard 32.000

∼

32.016 mm (1.2598

∼

1.2605 in.)


•

Measure the inside diameter [A] of the balancer shaft bearing on the crankcase cover at several points.

If inside diameter is more than the service limit, replace the crankcase cover with a new one.

Balancer Shaft Bearing Inside Diameter (Crankcase cover)

Standard 32.000

∼

32.016 mm (1.2598

∼

1.2605 in.)




Breather

The function of the breather is to create a negative pressure in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to prevent blow-by gases from emitting in the air. The blow-by gases are drawn into the clean side of the air cleaner through the crankcase and the cylinder head and mixed with the clean air flow, and subsequently comes into the combustion chamber through the carburetor.

Oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase, and secondly separated from the gases in the breather chamber, and then brought back to the crankcase.


Breather

Breather Valve Removal

•

Remove the cylinder head assembly (see Cylinder Head

Assembly Removal in the Engine Top End chapter).

•

Unscrew the breather valve screw [A].


Breather Valve Installation

•

Install the reed valve [A] and back plate [B] , Then tighten the breather valve screw [C].

Torque - Breather Valve Screw: 3.4 N·m ( 0.35 kgf·m, 30 in·lb)

•

Install the cylinder head assembly (see Cylinder Head Assembly Installation in the Engine Top End chapter).

Breather Valve Inspection

•

Remove the breather valve (see Breather Valve Removal).

•

Inspect the reed valve for breakage, hair cracks or distortion, replace it if necessary.

•

Inspect the back plate for damage or rough contact surface, replace it if necessary.

•

Inspect the valve seating surface. The surface should be free of nicks or burrs.

•

Align center of the valve seat with center of the reed valve and back plate, then tighten the breather valve screw.



TRANSMISSION 9-1

Transmission

Exploded View...................................

Specifications ....................................

Special Tools .....................................

Transmission Oil ................................

Transmission Oil Level Inspection

Transmission Oil Change.............

Transmission Case ............................

Transmission Case Removal .......

Transmission Case Installation ...

Transmission Case Disassembly .

Transmission Case Assembly......

Transmission and Shift Mechanism ..

Transmission Cable Installation ...

Transmission Shift Cable

Inspection..................................

Shift Rod Bending ........................

Shift Fork Ear and Shifter Groove

Wear..........................................

Transmission and Shift

Mechanism Inspection ..............

2WD/4WD Shift Mechanism

(KAF400-A/C) .................................

2WD/4WD Shift Cable

Adjustment ................................

2WD/4WD Shift Cable

Lubrication.................................

2WD/4WD Shift Cable Inspection


9-25

9-26

9-27

9-27

9-27

9-28

9-2

9-8

9-9

9-10

9-10

9-10

9-11

9-11

9-12

9-13

9-17

9-24

9-24

9-25

9-25


Removal ....................................


Inspection..................................

Differential Gears and Shift

Mechanism .....................................


Adjustment ................................


Lubrication.................................

Differential Shift Cable Inspection

Differential Shift Mechanism

Removal ....................................


Installation .................................


Inspection..................................

Differential Gear Removal............

Differential Gear Installation.........

Differential Gear Inspection .........

Bearings and Oil Seal........................

Bearing Replacement ..................

Ball Bearing Inspection ................

Needle Bearing Inspection...........

Oil Seal Inspection .......................

Transmission Sectional Figure ..........

9-28

9-28

9-29

9-29

9-29

9-30

9-30

9

9-31

9-31

9-31

9-32

9-33

9-34

9-34

9-34

9-34

9-34

9-35


9-2 TRANSMISSION

Exploded View


Exploded View

1. Differential Shift Cable

2. Transmission Cable

3. 2WD/4WD Shift Cable (KAF400-A/C)





Exploded View


Exploded View

No.

Fastener

1 Transmission Cable Holder Bolts



4 Transmission Case Bolts

5 Speed Sensor Cap Bolt

6 Transmission Oil Drain Plug

7 Cover Screws

8 Oil Line Plug

9 Shift Shaft Lever Bolt

10 Differential Shift Cable Holder Bolts

11 Plug Bolt (except Europe Model)

12 Shift Shaft Stop Bolt

13 Differential Shift Shaft Nut

14 Neutral Switch

15 Reverse Switch (Europe Model)

16 Positioning Bolt

G: Apply Grease


O: Apply engine oil.



4.0

9.8

13.5

8.8

15

8.8

20

15

15

25

N·m

41.5

28

55

8.8

8.8

15

0.40

1.0

1.4

0.90

1.5

0.90

2.0

1.5

1.5

2.5

Torque kgf·m

4.2

2.9

5.6

0.90

0.90

1.5

ft·lb

31

21

41

78 in·lb

78 in·lb

11

35 in·lb

87 in·lb

10

78 in·lb

11

78 in·lb

14

11

11

18

Remarks

L

L

L



Exploded View



Exploded View

No.

Fastener

Torque kgf·m

5.8

ft·lb

42

Remarks

1 Differential Gear Housing Bolts

N·m

57 L


MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1).

O: Apply engine oil.

R: Replacement Part (Fuel Pump Gasket)



Specifications

Item


Type

Viscosity

Standard

API "GL-5" Hypoid gear oil

SAE90: above 5°C (41°F) or

SAE80: below 5°C (41°F)

Service Limit

– – –

– – –

Capacity:

KAF400-A/C

KAF400-B

2.4 L (2.5 US qt)

2.2 L (2.3 US qt)

– – –

– – –

Oil Level Between H and L lines on dipstick – – –

Transmission and Shift

Mechanism

Shift Fork Ear Thickness 5.9

∼

6.0 mm (0.2322

∼

0.2362 in.) 5.8 mm (0.228 in.)

Shifter Groove Width 6.05

∼

6.15 mm (0.2382

∼

0.2421 in.) 6.25 mm (0.2462 in.)

Reverse Chain 20-link Length 190.50

∼

190.97 mm (7.500

∼

7.518 in.) 193.4 mm (7.614 in.)

2WD/4WD Shift Mechanism

Shifter Block Outside Diameter 13.95

∼

14.00 mm (0.549

∼

0.551 in.)

Shifter Groove Width 14.0

∼

14.2 mm (0.551

∼

0.559 in.)

Differential Gears and Shift

Mechanism

Shift Shaft Pin Diameter

Shifter Groove Width

8.4

∼

8.6 mm (0.331

∼

0.339 in.)

9.0

∼

9.1 mm (0.354

∼

0.358 in.)

13.8 mm (0.543 in.)

14.3 mm (0.563 in.)

8.3 mm (0.327 in.)

9.2 mm (0.362 in.)


Special Tools


57001-144

Oil Seal & Bearing Remover:

57001-1058


57001-1129


Socket Wrench, Hex 41:

57001-1402

Alignment Jig:

57001-1631




CAUTION

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 gauge [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



Transmission Case

Transmission Case Removal

•

Drain:

Transmission Oil (see Transmission Oil Change in the

Periodic Maintenance chapter)

•

Remove:


Propeller Shafts (KAF400-A/C, see Final Drive chapter)

Bevel Gear Case (KAF400-A/C, see Final Drive chapter)

Rear Wheels (see Wheels/Tires chapter)

Rear Brake Panels (see Brakes chapter)

Rear Shock Absorbers (See Suspension chapter)


•

Remove:

Control Panel Assembly [A] (see Fuel System chapter)

Transmission Shift Shaft Lever [B] and Bracket [C]


•

Remove:

Differential Shift Cable Bracket [A] and Cable End [B]

2WD/4WD Shift Cable Bracket [C] and Cable End [D]

(KAF400-A/C)

Neutral Switch Lead Connector [E]

Reverse Switch Lead Connector (Europe Model)

•

Hold the transmission case on a stand or jack.

•

Loosen:

Rear Axle Bracket Flange Bolts [A] (Left and Right)

•

Remove:

Rear Axle Bracket Bolts [B] (Left and Right)




•

Remove:

Connecting Plate Bolts [A] and Washers

Connecting Plate [B]

•

Lift up the transmission case until the axle holder is removed.

•

Remove:

Rear Axle Bracket Bolts (Left and Right)

Rear Axles and Rear Axle Bracket Assemblies [A] (Left and Right)

•

Remove:

Transmission Case [A]

Transmission Case Installation

•

Hold the transmission case on a stand or jack and hold it.

•

Install:

Rear Right Axle and Rear Axle Bracket Assembly [A]

Rear Axle Bracket Flange Bolts (temporarily)

•

Set the differential shift lever [B] to differential lock position and install the rear left axle and rear axle bracket assembly [C].

•

Install:

Rear Axle Bracket Bolts (temporarily)



•


Connecting Plate Bolts (M10) [A]

Connecting Plate Bolts (M8) [B]

•

Install the washer and tighten the connecting plate bolts

(M10 and M8) lightly by hand.

•

Install the alignment jig and tighten the bolts (see Engine

Installation in the Engine Removal/Installation chapter).

Special Tool - Alignment Jig: 57001-1631

•

Tighten:

Torque - Connecting Plate Bolts (M10): 55 N·m (5.6 kgf·m,

41 ft·lb)

Connecting Plate Bolts (M8): 28 N·m (2.9 kgf·m,

21 ft·lb)

If the engine was removed, refer to the Engine Removal/Installation chapter.

•

Tighten the rear axle bracket flange bolts [A] while turning the axle bracket [B] toward the front side [C].

Torque - Rear Axle Bracket Flange Bolts: 49 N·m (5.0


Rear Axle Bracket Bolts: 24.5 N·m (2.5 kgf·m, 18 ft·lb)

•

Remove the alignment jig.


Transmission Case Disassembly

•

Remove:

Bevel Gear Drive Gear (see Final Drive chapter)

Transmission Case (see Transmission Case Removal)

Transmission Case Bolts [A]

Transmission Case (Right) [B]




•

Remove:

Drive Shaft [A]

Differential Gear Assembly [B]

•

Remove:

Positioning Bolt [A]

Washer [B]

Spring [C]

Steel Ball [D]

•

Remove:

Pin [A]

•

Push up the shift arm [B].

•

Remove the following parts at same time.

Mission Shaft [A]

Driven Shaft [B]

Shift Rod [C]

Reverse Chain [D]

•

Remove:

Shift Arm [A]

Snap Pins [B]

Governor Arm [C]

Governor Assembly [D] (see Fuel System chapter)



•

Using the socket wrench [A] remove the bearing holder

[B].

Special Tool - Socket Wrench, Hex 41: 57001-1402


•

Remove:

Circlip [A] of Transmission Shaft [B]


•

Remove:

Collar [C]

Sprocket [D]

•

Remove:

Needle Bearing [A]

Spacer [B]

Shifter [C]

•

Remove:

Circlip


•

Remove:

Washer [A]

Spacer [B]

Spacer [C]

Spacer (54.3×1.0)

High Gear [D]

•

Remove:

Spacer (54.3×1.0) [A]

Needle Bearing [B]

Low Gear [C]

Needle Bearing [D]




•

Remove:

Needle Bearing [A]

Washer [B]



Transmission Case Assembly

•

Assemble the right transmission case as shown.

Right Transmission Case [A]

Ball Bearing [B]

Oil Seal [C]

6 mm (0.24 in.) [D]

Ball Bearing [E]

Seal Side [F]

Ball Bearing [G]

Ball Bearing [H]

Oil Seal [I]

29.5 mm (1.16 in.) [J]

Cover [K]

Cover Screws [L]

•

Tighten:

Torque - Cover Screws: 4 .0 N·m (0.40 kgf·m, 35 in·lb)





•

Assemble the left transmission case as shown.

Left Transmission Case [A]

Ball Bearing [B]

Ball Bearing [C]

Seal Side [D]

Ball Bearing [E]

Bearing Holder [F] (Refer to the following.)

Shifter [G]

Lever [H]

Bolt [I]

Ball Bearing [J]

○

Install the ball bearing [J] after assembling the shifter [G], lever [H] and bolt [I].

Oil Seal [K]

13 mm (0.51 in.) [L]

Governor Shaft [M]

Long Side [N]



○


Bearing Holder [F]

○

Install the bearing holder so that the deep recess [A] faces outward.

○

Tighten:

Torque - Bearing Holder: 137 N·m (14 kgf·m, 101 ft·lb)


•

Install the oil seals to the left transmission case as shown.

Left Transmission Case [A]

Oil Seal [B]

0.5 mm (0.02 in.) [C]

Bushing [D]

Flush [E]

Oil Seal [F]

Flush [G]

Oil Seal [H]

Flush [I]

Oil Line Plug [J]

•

Apply a non-permanent locking agent to the plug, and tighten it.

Torque - Oil Line Plug: 9.8 N·m (1.0 kgf·m, 87 in·lb)





•

Replace all circlips that were removed with new ones.

NOTE

○

To install a circlip without damage, first fit the circlip onto the shaft and then expand it just enough to install.

Hence, use a suitable gear to push the circlip into place.

•

Apply transmission oil:

Ball and Needle Bearings

Bearing of Shaft

Slide of Shaft

Slide of Governor Gear

Slide and Tooth of Gears

Shifters

Spacers

•

Apply Grease:

Lip of Oil Seals

O-rings

•

Check that each gear, sprocket, and shifter spins or slides freely on its shaft without binding after assembly.

•

Install:

Governor Assembly (see Fuel System chapter)

Governor Shaft

Shift Arm



•

Install:

Mission Shaft [A]

Circlip [B]

Collar [C]

Reverse Driven Sprocket [D]

Spacer [E]

Shifter [F]

Circlip [G]

Washer [H]

Spacer [I]

High Gear [J]

Needle Bearing [K]

Low Gear [L]

Drive Gear [M]

Spacer [N]

Spacers [O]

Needle Bearings [P]

Needle Bearing [Q]

Washer [R]





•

Install the following parts on the drive shaft [A].

Pin [B]

Governor Drive Gear [C]

○

Install the governor drive gear so that the flat side [D] faces to the circlip.

•

Install:

Circlip [A]

Special Tool - Outside Circlip Pliers [B]: 57001-144

•

Install:

Shift Arm [A]

Mission Shaft [B], Driven Shaft [C], Shift Rod [D] and

Reverse Chain [E]

•

Insert the pin of the shift fork [A] into the shift arm [B].

•

Install:

Pin [C]

•

Install:

Differential Gear Assembly [A]

Drive Shaft [B]

•

Check to see that the transmission case dowel pins [C] are in place.



•

Apply liquid Gasket:

Transmission Case Mating Surface [A]

Sealant - Three Bond 1216B

•

Tighten:

Torque - Transmission Case Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)




Transmission and Shift Mechanism

Transmission Cable Installation

•

Put the shift lever [A] in the “N” (Neutral) position.

•

Set the shift arm [A] in the neutral position.

○

Align the punch mark [B] of the shift arm with the boss [C] of the transmission case.

•

Screw in the transmission cable end fully to the joint [A] of the shift shaft lever [B].

•

Pass the cable through the cable bracket [C].

•

Install the shift shaft lever [A] so that the slit [B] of the lever aligns with the punch mark [C] of the shift arm.

•

Tighten the shift shaft lever bolt [D].

Torque - Shift Shaft Lever Bolt: 13.5 N·m (1.4 kgf·m, 10 ft·lb)

•

Push the cable [A] lightly rearward [B] to remove the cable free play.

•

Tighten the nut [C] by hand and fit the nut to cable bracket

[D] to remove the cable free play.

•

Tighten:

Nut [E]

Nut [F]



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.


Shift Rod Bending

•

Visually inspect the shift rod [A] and shift fork [B].

If the fork is bent, replace the shift rod with a new one.

A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.

[C] 90°

Shift Fork Ear and Shifter Groove Wear

•

Measure the thickness of the shift fork ears [A], and measure the width of the gear groove and shifter.

If the thickness of a shift fork ear is less than the service limit, the shift rod must be replaced.

Shift Fork Ear Thickness

Standard: 5.9

∼

6.0 mm (0.2322

∼

0.2362 in.)


If the groove is worn over the service limit, the shifter must be replaced.

Shifter Groove Width [A]

Standard: 6.05

∼

6.15 mm (0.2382

∼

0.2421 in.)





Transmission and Shift Mechanism Inspection

•

Visually inspect:

Gears

Dogs of Gear and Shifter

If they are damaged or worn excessively, replace them.

Reverse Chain 20-Link Length [B]


∼

190.97 mm (7.500

∼

7.518 in.)


[A] Force

[C] 1st Pin

[D] 2nd Pin

[E] 21st Pin


2WD/4WD Shift Mechanism (KAF400-A/C)

2WD/4WD Shift Cable Adjustment

•

Put the shift lever [A] in the 2WD position.


•

Install the 2WD/4WD shift cable [A] to the shift shaft lever

[B] and cable bracket [C].

•

Put the shift lever [A] in the 4WD position.

•

Push the shift shaft lever [A] to the forward (4WD Position), and make the engagement of the shifter maximum while turning the propeller shaft by hand.

•

Turn the nut [B] with fingers and pull slightly the inner cable, and tighten the nut [C].

•

Put the shift lever in the 2WD position.

•

Confirm to return the shift shaft lever to 2WD position.

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.



2WD/4WD Shift Mechanism (KAF400-A/C)

2WD/4WD Shift Cable Inspection

•

With the cable disconnected at both ends, the cable should move freely [A] within the cable housing.


2WD/4WD Shift Mechanism Removal

•

Refer to Bevel Gear Case in the Final Drive chapter.

2WD/4WD Shift Mechanism Inspection

•

Visually inspect:

Dogs on Shifter [A]

Shifter Groove [B]

Dogs on Driven Bevel Gear [C]

Shifter Block [D]


Shifter Block Outside Diameter

Standard: 13.95

∼

14.00 mm (0.549

∼

0.551 in.)


Shifter Groove Width

Standard: 14.0

∼

14.2 mm (0.551

∼

0.559 in.)



Differential Gears and Shift Mechanism

Differential Shift Cable Adjustment

•

Put the shift lever [A] in the UN-LOCK position.

•

Install the differential shift cable [A] to the shift shaft lever

[B] and cable bracket [C].


•

Put the shift lever [A] in the LOCK position.

•

Push the shift shaft lever [A] to the forward (LOCK position), and make the engagement of the shifter maximum while turning the drive shaft [B] by hand.

•

Turn the nut [C] with fingers and pull slightly the inner cable, and tighten the nut [D].

•

Put the shift lever in the UN-LOCK position.

•

Confirm to return the shift shaft lever to UN-LOCK position.

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.


Differential Shift Mechanism Removal

•

Remove:

Transmission Case (splitting, see Transmission Case

Disassembly)

Differential Gear [A]

•

Remove:

Shift Shaft Lever Stop Bolt [A]

Differential Shift Shaft Nut [B]

Differentia Shift Shaft Lever [C] and Spring [D]

•

Pull up the differential shift shaft [A].

•

Remove:

Shifter [B]

•

Remove:

Differential Shift Shaft [A]



Differential Shift Mechanism Installation

•

Install:

Differential Shift Shaft [A]

Shifter [B]

Shift Shaft Lever Stop Bolt [C]

•

Tighten:

Torque - Shift Shaft Lever Stop Bolt: 8.8 N·m (0.90 kgf·m,

78 in·lb)

•

Align the mark [A] on the shaft with the mark [B] on the lever as shown.

•

Tighten:

Torque - Differential Shift Shaft Nut: 20 N·m (2.0 kgf·m, 14 ft·lb)


Differential Shift Mechanism Inspection

•

Visually inspect:

Splines on Drive Shaft [A]

Splines on Shifter [B]

Dogs on Shifter

Shifter Groove

Shift Shaft Pin [C]

Dogs on Differential Gear Housing [D]


Shift Shaft Pin Diameter [A]

Standard: 8.4

∼

8.6 mm (0.331

∼

0.339 in.)


Shifter Groove Width [B]

Standard: 9.0

∼

9.1 mm (0.354

∼

0.358 in.)


Differential Gear Removal

•

Remove:

Transmission Case (split, see Transmission Case Disassembly)

Differential Gear Assembly [A]




•

Remove:

Differential Gear Housing Bolts [A]

Final Gear [B]

•

Remove:

Housing [A]

Knock Pin [B]

Side Gear [C]

Spacer [D]

•

Remove:

Retaining Pin [A]

Pinion Gear Shaft [B]

Pinion Gears [C]

•

Remove:

Side Gear [A]

Differential Gear Installation

•

Apply molybdenum disulfide oil:

Side Gears

Pinion Gears

•


Differential Gear Housing Bolts

•

Tighten:

Torque - Differential Gear Housing Bolts: 57 N·m (5.8




Differential Gear Inspection

•

Visually inspect the differential gears.

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 a press and the bearing driver set, install the new bearings and/or new oil seals.


Ball Bearing Inspection

•

Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

•

Turn [A] each bearing back and forth while checking for roughness or binding.

If roughness or binding is found, 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 Sectional Figure












WHEELS/TIRES 10-1

Wheels/Tires


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tool ............................................................................................................................

Wheel Alignment ....................................................................................................................

Toe-in Adjustment .............................................................................................................

Wheels (Rims) ........................................................................................................................

Wheel Removal.................................................................................................................

Wheel Installation..............................................................................................................

Wheel (Rim) Inspection.....................................................................................................

Wheel (Rim) Replacement................................................................................................

10-2

10-4

10-5

10-6

Tires........................................................................................................................................

Tire Removal ....................................................................................................................

Tire Installation .................................................................................................................

10-9

10-9

10-9

Tire Wear Inspection .........................................................................................................

10-10

10-6

10-7

10-7

10-7

10-7

10-8

10


10-2 WHEELS/TIRES

Exploded View



Exploded View

No.

Fastener

1 Wheel Nuts


W: Apply a soap and water solution, or water.

N·m

34

Torque kgf·m

3.5

ft·lb

25

Remarks



Specifications

Item

Wheel Alignment

Toe-in

Tie-rod Length

(Distance Between Flange

End and Locknut)

Tires

Standard Tire:

KAF400-A/C

Front

Rear

KAF400-B

Front

Rear

Tire Air Pressure (when cold):

Front

Rear

KAF400-A/C

KAF400-B

Maximum Tire Air Pressure

(to seat beads, when cold)

Tire Tread Depth

Standard

0

∼

20 mm (0

∼

0.79 in.) at 1G about 34 mm (1.34 in.)

24 × 9.00 – 10

DUNLOP KT869M, Tubeless

24 × 11.00 – 10


22 × 9.00 – 10


22 × 11.00 – 10


46.7 kPa (0.5 kgf/cm², 7 psi)

98.1 kPa (1.00 kgf/cm², 14.2 psi)

96.7 kPa (0.99 kgf/cm², 14.0 psi)

250 kPa (2.5 kgf/cm², 36 psi)

– – –

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

3 mm (0.12 in.)


Special Tool

Jack:

57001-1238




Wheel Alignment

Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is greater than B

(Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. 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 [A] 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.

•

Check the length [A] of the tie-rod distance between the flange end [B] and the locknut [C].

Tie-rod Length (distance between flange end and locknut)

Standard: about 34 mm (1.34 in.)

If the length is out of the specified, adjust the tie-rod length.

•

Loosen the locknut and turn the adjusting rod [D] to achieve the specified value.

NOTE

○

The toe-in will be near the specified range, if the tie-rod length is the specified value on the left and right.

•

Tighten:

Torque - Tie-rod 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).

•

Support the vehicle on a stand or a jack so that the wheels are off the ground.

Special Tool - Jack: 57001-1238

•

Remove:

Wheel Nuts

Wheel(s)

Wheel Installation

•

Check the tire rotation mark [A] on the tire, and install the wheel accordingly.

NOTE

○

The direction of the tire rotation [B] is shown by an arrow on the tire sidewall.

•

Position the wheel so that the valve stem [A] is toward the outside of the vehicle.

•

Tighten:

Torque - Wheel Nuts: 34 N·m (3.5 kgf·m, 25 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.


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.



Wheels (Rims)

Wheel (Rim) Replacement

•

Remove the wheel (see Wheel Removal).

•

Remove the tire from the rim.

•

Remove the valve stem and discard it.

CAUTION

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]

•

Install a new air valve in the new rim.

○

Remove the valve cap, lubricate the stem with a soap and water solution, and pull the stem [A] through the rim from the inside out until it snaps into place.

CAUTION

Do not use engine oil or petroleum distillates to 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.

CAUTION

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.

CAUTION

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

Do not inflate the tire to more than the maximum tire air pressure. Overinflation can explode the tire with possibility of injury and loss of life.



Tires

•

Check to see that the bead lines [A] on both sides of the tire are parallel with the rim flanges [B].

If the bead lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and re-

• inflate 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 [A].

NOTE

○

Kawasaki provides the air pressure gauge (P/N 52005

-1031) as the owner’s tool.

Tire Air Pressure (when cold)

Front 46.7 kPa (0.5 kgf/cm², 7 psi)

Rear:

(KAF400-A/C) 98.1 kPa (1.00 kgf/cm², 14.2 psi)

(KAF400-B) 96.7 kPa (0.99 kgf/cm², 14.0 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

Do not operate the vehicle with the water and soap, or water still around the tire beads. They will cause tire separation, and a hazardous condition may result.

WARNING

Inflate both front tires to the same pressure and both rear tires to the same pressure. Operating with unequally or improperly pressurized tires can adversely affect steering or handling.

Tire Wear Inspection

•

Refer to the Wheels/Tires in the Periodic Maintenance chapter.


FINAL DRIVE 11-1

Final Drive


Exploded View...................................

Specifications ....................................

Special Tools .....................................

Front Final Gear Case (KAF400-A/C)

11-2

11-6

11-7

11-8

Front Final Gear Case Oil Level

Inspection .................................

Front Final Gear Case Oil

Change......................................

11-8

Front Final Gear Case Removal ..

Front Final Gear Case Installation

Front Final Gear Case

Disassembly..............................

11-8

11-8

11-9

11-9

Front Final Gear Case Assembly.

11-11

Differential Unit Disassembly .......

11-12

Differential Unit Assembly............

11-14

LSD Clutch Torque Inspection .....

11-15

LSD Clutch Plate Inspection ........

11-15

Pinion Gear Unit Disassembly .....

11-16

Pinion Gear Unit Assembly ..........

11-16

Front Final Bevel Gear

Adjustment ................................

11-17

Bevel Gear Inspection..................

11-23

Differential Gear Inspection .........

11-23


11-23

Oil Seal Inspection .......................

11-23

Bevel Gear Case (KAF400-A/C)........

11-24

Driven Bevel Gear Removal ........

11-24

Driven Bevel Gear Installation .....

11-24

Driven Bevel Gear Disassembly ..

11-24

Driven Bevel Gear Assembly .......

11-25

Drive Bevel Gear Removal ..........

11-27

Drive Bevel Gear Installation .......

11-28

Bevel Gear Adjustment ...............

11-28

Bevel Gear Inspection..................

11-31

Ball Bearing/Oil Seal Inspection...

11-31

Propeller Shafts (KAF400-A/C) .........

11-32

Front Propeller Shaft Removal.....

11-32

Front Propeller Shaft Installation..

11-32

Rear Propeller Shaft Removal .....

11-34

Rear Propeller Shaft Installation ..

11-35

Propeller Shaft Inspection............

11-36

Axles..................................................

11-37

Front Axle Removal

(KAF400-A/C)............................

11-37

Front Axle Installation

(KAF400-A/C)............................

11-37

Front Axle Removal (KAF400-B) .

11-37

Front Axle Installation

(KAF400-B) ...............................

11-37

Rear Axle Removal ......................

11-38

Rear Axle Installation ...................

11-38

Axle Inspection.............................

11-38

Dust Boot Inspection

(KAF400-A/C)............................

11-38

Front Axle Joint Boot

Replacement (KAF400-A/C) .....

11-39


11-44

Grease Seal Inspection................

11-45

11


11-2 FINAL DRIVE

Exploded View


Exploded View

No.

Fastener

1 Front Final Gear Case Oil Filler Cap

2 Front Final Gear Case Oil Drain Plug

3 Pinion Gear Nut

4 Pinion Gear Bearing Holder

5 Differential Gear Housing Bolts

6 Ring Gear Cover Bolts M8

7 Ring Gear Cover Bolts M10

8 Rear Axle Bracket Bolts

9 Rear Axle Bracket Flange Bolts

G: Apply Grease.



O: Apply oil.



N·m

29

20

156

98

49

25

47

24.5

49

Torque kgf·m

3.0

2.0

16

10

5.0

2.6

4.8

2.5

5.0

ft·lb

22

14

115

72

36

19

35

18

36

Remarks

L



Exploded View



Exploded View

No.

1

2

3

4

5

6

7

8

Fastener

Bevel Gear Case Bolts

Yoke Stop Bolt


Bearing Screw

Drive Bevel Gear Nut

2WD/4WD Shift Shaft Nut

2WD/4WD Shift Cable Holder Bolts

Bearing Housing Bolts

N·m

20

8.8

118

137

137

20

8.8

41.5

Torque kgf·m

2.0

0.90

12

14

14

2.0

0.90

4.2

ft·lb

14

78 in·lb

87

101

101

14

78 in·lb

31

Remarks

MO

L

MO

L

G: Apply Grease.



MO: Apply molybdenum disulfide oil. (The weight ratio of the mixture between engine oil and disulfide grease is 10 : 1)

O: Apply oil.




Specifications

Item

Front Final Gear Case

Gear Case Oil:

Type

Standard

Viscosity

API "GL-5 or GL-6" hypoid gear oil for LSD

(Limited Slip Differential gears)

SAE90 (GL-6) or SAE140 (GL-5)

Capacity 0.4 L (0.4 US qt)

Oil Level Filler opening level

LSD Clutch Torque

Outside Friction Plate

4.9

∼

13 N·m (0.5

∼

1.3 kgf·m, 43

∼

110 in·lb)

1.3

∼

1.4 mm (0.051

∼

0.055 in.)

Thickness

Inside Friction Plate Thickness 1.7

∼

1.8 mm (0.067

∼

0.071 in.)

Pinion Gear Preload Torque

Bevel Gear Backlash

0.5 N·m (0.05 kgf·m, 4.4 in·lb) or less

0.06

∼

0.18 mm (0.0024

∼

0.0071 in.)

(at pinion gear spline)

Bevel Gear Case

Bevel Gear Backlash 0.35

∼

0.50 mm (0.0138

∼

(at driven bevel gear tooth)

0.0197 in.)

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –


Special Tools

Bearing Puller:

57001-135


57001-144

Socket Wrench:

57001-1283

Socket Wrench, Hex 48:

57001-1401

Pinion Gear Holder:

57001-1632

Snap Ring Guide, 20:

57001-1633


Snap Ring Guide, 22:

57001-1634

Bevel Gear Holder:

57001-1638

Bevel Gear Holder:

57001-1639



Front Final Gear Case (KAF400-A/C)

Front Final Gear Case Oil Level Inspection

•

Remove:

Filler Cap [A]

CAUTION

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 [A] of the filler opening [B].

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 [C] is in place, and tighten the filler cap.

Torque - Front Final Gear Case Oil Filler Cap: 29 N·m (3.0


Front Final Gear Case Oil Change

•

Refer to Final Drive section in the Periodic Maintenance chapter.

Front Final Gear Case Removal

•

Remove:

Front Guard Cover (see Frame chapter)

Front Final Gear Case Oil (drain, see Front Final Gear

Case Oil Change in the Periodic Maintenance chapter)

Front Axles (see Front Axle Removal)

•

Loosen:

Front Final Gear Case Lower Mounting Bolts [A]

•

Remove:

Front Final Gear Case Mounting Bolt [B] and Nuts.

•

Remove:

Bracket Bolts [A]

Bracket [B]

Front Final Gear Case Lower Bolts and Nuts



•

Remove:

Gear Case Breather Hose [A]

•

Move the front final gear case [B] toward the front [C], and remove the case from yoke [D] of the propeller shaft.


Front Final Gear Case Installation

•

Insert the pinion gear shaft [A] of the gear case in the yoke

[B], and put the gear case on the frame.

•

Route the gear case breather hose correctly according to the Appendix chapter.

•

Adjust the front final gear case oil (see Front Final Gear

Case Oil Change the Periodic Maintenance chapter).

Front Final Gear Case Disassembly

•

Remove:

Front Final Gear Case (see Front Final Gear Case Removal)

Circlip [A]


•

Remove:

Oil Seal [C]

•

Pry open the staking [A] of the pinion gear bearing holder

[B] with a small chisel.

•

Unscrew the pinion gear bearing holder, using the socket wrench [A].





•

Remove:

Ring Gear Cover Bolts M8 [A] (first)

Ring Gear Cover Bolts M10 [B]

Ring Gear Cover [C]

○

Using the ply points [D], split the front final gear case.

If the case seems too difficult to break free, install suitable

M8 bolts [A] as shown. And then drive the bolt end using a copper mallet.

•

Remove:

Ring Gear Assembly [A]

Shim [B]

•

Pry put the pinion gear unit [A].

•

Remove:

Pinion Gear Unit [A]

Shim [B]

Ring Gear Assembly [C]



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.

•

Assemble the gear case temporarily for the gear backlash adjustment.

○

Clean the mating surface of the front final gear case and cover.

○

Install:

Pinion Gear Unit [A]

Shim [B]

Ring Gear Assembly [C]

○

Install:

Shim [A]


○

Tighten:

Torque - Ring Gear Cover Bolts M10 [A]: 47 N·m (4.8 kgf·m,

35 ft·lb)

Ring Gear Cover Bolts M8 [B]: 25 N·m (2.6 kgf·m,

19 ft·lb)

○

Tighten:

Torque - Pinion Gear Bearing Holder [A]: 98 N·m (10 kgf·m,

72 ft·lb)


○

Adjust the gear backlash and tooth contact pattern (see

Front Final Bevel Gear Adjustment).

○

Split the front final gear case (see Front Final Gear Case

Disassembly)




•

Clean the mating surface of the front final gear case and cover.

•

Apply liquid gasket to mating surface [A] and flange [B] of the gear case cover.

Sealant - Kawasaki Bond 92104-1063 or

Three Bond TB1216

•

Tighten:

Torque - Ring Gear Cover Bolts M10 [A]: 47 N·m (4.8 kgf·m,

35 ft·lb)

Ring Gear Cover Bolts M8 [B]: 25 N·m (2.6 kgf·m,

19 ft·lb)

•

Stake [A] the pinion gear bearing holder [B] with a punch to secure it.

•

Apply grease to the oil seal lips, and install it in the gear case.

Oil Seal [A]

•

Install:

Circlip [B] (second groove [C] as shown)


Differential Unit Disassembly

•

Remove:

Differential Unit (see Front Final Gear Case Disassembly)


Differential Gear Unit [B]




•

Remove:

Bevel Gear [A]

•

Remove:

Inside Friction Plates [A]

Steel Plate [B]

Outside Friction Plate

•

Remove:

Clutch Springs [A]

Washer [B]

•

Remove:

Clutch Spring Shims [A]

•

Remove:

Spring Pins [A]

Pinion Shaft [B]

Bevel Gears [C]

Collar [D]

Washer [E]




Differential Unit Assembly

•

Inspect the LSD clutch plates and (see LSD Clutch Plate

Inspection) and other differential unit parts. Replace any damaged parts.

•

Apply specified gear oil to the differential unit parts.

•

Note direction and position of the friction plates and clutch spring.

Clutch Spring Shims [A]

Washer [B]

Clutch Springs [C]

Outside Friction Plate [D]

Steel Plate [E]

Inside Friction Plate [F]

•

Install the bevel gear [A] so that the teeth [B] fit in the grooves [C] fit.

•

Install the LSD clutch case [A] on the ring gear [B].

○

Align the bolt holes [C].

•

Install the differential gear unit [A] on the LSD clutch case

[B].

○

Align the small holes [C].




•



•

Finger-tighten the all bolts first.

•

Tighten:

Torque - Differential Gear Housing Bolts: 49 N·m (5.0


LSD Clutch Torque Inspection

•

After assembling the differential unit and ring gear [A], check the LSD clutch torque.

•

Insert both front axles in the unit.

•

Hold one of the front axles with a vise.

•

Install the hub nut on the other axle.

•

Measure the clutch torque using a torque wrench [B]. Turn the wrench evenly.

○

The clutch torque is the mean torque reading during about a quarter turn of the wrench.

LSD Clutch Torque

Standard: 4.9

∼

13 N·m (0.5

∼

1.3 kgf·m, 43

∼

110 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(s).

•

Also, check the clutch plates and replace them as necessary (see Clutch Plate Inspection).

•

To increase clutch torque, increase the thickness of the shim(s).

○

Change the thickness a little at a time.

•

Recheck the clutch torque and readjust as necessary.

Thickness Part Number

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

92180-1214

92180-1215

1.4 mm (0.055 in.)

1.6 mm (0.063 in.)

1.8 mm (0.071 in.)

92180-1216

92180-1217

92180-1218

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, replace the friction plates and steel plates as a set.

Outside Friction Plate Thickness [A]

Standard: 1.3

∼

1.4 mm (0.051

∼

0.055 in.)

Inside Friction Plate Thickness [B]

Standard: 1.7

∼

1.8 mm (0.067

∼

0.071 in.)




Pinion Gear Unit Disassembly

•

Remove the pinion gear unit (see Front Final Gear Case

Disassembly).

•

Holding the pinion gear unit with the pinion gear holder

[A], unscrew the pinion gear nut [B]

Special Tool - Pinion Gear Holder: 57001-1632

•

Remove the ball bearing as necessary.

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 bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a bearing, replace the bearing.

•

Be sure to check and adjust the pinion gear preload and the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see Front Final

Bevel Gear Adjustment).

•

Install:

Pinion Gear [A]

Shim [B]

Ball Bearing [C]

•

Apply a non-permanent locking agent to the pinion gear nut [D].

•

Tighten the pinion gear nut so that the stepped side [E] faces outward.

Torque - Pinion Gear Nut: 156 N·m (16 kgf·m, 115 ft·lb)



Front Final Bevel Gear Adjustment

In order to prevent one gear from moving away from the other gear under load, the pinion gear must be properly pre-

loaded. 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 pinion gear 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.

Pinion Gear Preload Adjustment:

•

Check and adjust the pinion gear preload in the following cases.

○

When any of the parts listed below are replaced with new ones.

Pinion Gear

Shims

Ball Bearings

•

Install the pinion gear and tighten the pinion gear nut to the specified torque.

Torque - Pinion Gear Nut: 156 N·m (16 kgf·m, 115 ft·lb)

•

Do not install the oil seal, and do not lock the bearing holder until the correct preload is obtained.

CAUTION

To start with, choose a shim so that the bevel gears are just SNUG with NO play but also with NO preload.

An over-preload on the gears could damage the gears.

•

Measure the pinion gear preload. The preload is the force or torque which is needed to start the gear shaft turning.

Torque Wrench [A]

Special Tool - Pinion Gear Holder [B]: 57001-1632





If the preload is out of the specified range, replace the ring gear shim(s).

○

To increase preload, decrease the size of the shim(s). To decrease preload, increase the size of the shim(s).

○


•

Recheck the preload, and readjust as necessary.

•

Measure the preload using a torque wrench [A].

Pinion Gear Preload Torque:

0.5 N·m (0.05 kgf·m, 4.4 in·lb) or less

Special Tool - Pinion Gear Holder [B]: 57001-1632

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 apply liquid gasket 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 a spline of pinion gear shaft to check gear backlash shown.

•

To measure the backlash, move the pinion gear back and forth while holding the front axle steady. The difference between the highest and the lowest gauge reading is the amount of backlash.

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).

○


•

Recheck the backlash, and readjust as necessary.

•

Move the pinion gear shaft back and forth [A].

Dial Gauge [B]

Bevel Gear Backlash

Standard: 0.06

∼

0.18 mm (0.0024

∼

0.0071 in.) (at pinion gear spline)



Front Final Gear Case (Backlash-Related Parts)


1. Front Final Gear Case Cover

2. Differential Unit

3. Ring Gear Right Shim

4. Ball Bearings

5. Ring Gear

6. Ring Gear Case

7. Ring Gear Left Shim

8. Pinion Gear

9. Pinion Gear Shim




Ring Gear Right Shims

Thickness

0.75 mm (0.0295 in.)

0.80 mm (0.0315 in.)

Part Number

92180-1254

92180-1255

Pinion Gear Left Shims

Thickness

1.75 mm (0.0689 in.)

1.80 mm (0.0709 in.)

Part Number

92180-1231

92180-1232

0.85 mm (0.0335 in.)

0.90 mm (0.0354 in.)

92180-1256

92180-1257

1.85 mm (0.0728 in.)

1.90 mm (0.0748 in.)

92180-1233

92180-1234

0.95 mm (0.0374 in.) 92180-1258 1.95 mm (0.0768 in.) 92180-1235

1.00 mm (0.0394 in.) (Primary) 92180-1259 2.00 mm (0.0787 in.) (Primary) 92180-1236

1.05 mm (0.0413 in.)

1.10 mm (0.0433 in.)

1.15 mm (0.0453 in.)

1.20 mm (0.0472 in.)

1.25 mm (0.0492 in.)

92180-1260

92180-1261

92180-1262

92180-1263

92180-1264

2.05 mm (0.0807 in.)

2.10 mm (0.0827 in.)

2.15 mm (0.0846 in.)

2.20 mm (0.0866 in.)

2.25 mm (0.0886 in.)

92180-1237

92180-1238

92180-1239

92180-1240

92180-1241

Pinion Gear Shims

Thickness

1.82 mm (0.0717 in.)

1.88 mm (0.0740 in.)

Part Number

92180-1219

92180-1220

1.94 mm (0.0764 in.) 92180-1221

2.00 mm (0.0787 in.) (Primary) 92180-1222

2.06 mm (0.0811 in.)

2.12 mm (0.0835 in.)

2.18 mm (0.0858 in.)

92180-1223

92180-1224

92180-1225



Tooth Contact Adjustment

•


•

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.

•

Assemble the front final gear case (see Front Final Gear

Case Assembly). Do not apply liquid gasket 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.

•

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.





Correct Tooth Contact Pattern: No adjustment is required.

Heel [A] Bottom [B] Top [C] Toe [D] Ring Gear [E] Pinion Gear [F]

Incorrect Tooth Contact Patterns (Example 1)

○

Decrease the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above. Repeat in 0.05 mm (0.002 in.) steps if necessary.


Incorrect Tooth Contact Patterns (Example 2)

○

Increase the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above. Repeat in 0.05 mm (0.002 in.) steps if necessary.




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.


•

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 is noisy, does not spin smoothly, or has any rough spots, replace it.

Oil Seal Inspection

•

Visually inspect the oil seal.





Bevel Gear Case (KAF400-A/C)

Driven Bevel Gear Removal

•

Remove:

Transmission Oil (drain, see Transmission Oil Change in the Periodic Maintenance chapter)

Left Rear Wheel (see Wheels/Tires chapter)

Rear Propeller Shaft (see Propeller Shaft Removal)

Bolts [A] and Cable Bracket [B]

2WD/4WD Shift Cable End [C]

•

Remove:

Bevel Gear Case Bolts [A]

Bevel Gear Case [B]

•

Remove:

Driven Bevel Gear Assembly [A]

Driven 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).

•

Check to see that the bevel gear case dowel pin [A] are in place.

•

Insert the shift shaft pin in the groove of the sifter, and install the bevel gear case.

•

Tighten:

Torque - Bevel Gear Case Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb)

Driven Bevel Gear Disassembly

•

Remove:

Driven Bevel Gear Assembly (see Driven Bevel Gear

Removal)

Snap Ring [A]

Oil Seal [B]



•

Pry open the toothed washer tab [A] on the driven bevel gear slotted nut [B] with a small chisel.


•

Unscrew the driven bevel gear slotted nut.

Special Tools - Bevel Gear Holder [A]: 57001-1638

Socket Wrench [B]: 57001-1283

•

Remove:


Washer

Toothed Washer

Ball Bearing [C]

Shifter [D]

•

Remove:

Ball Bearing [A]

Snap Ring [B]

Collar [C]

Driven Bevel Gear [D]

Driven Bevel Gear Assembly

•

Install:

Ball Bearing [A]

Toothed Washer [B]

Washer [C]

Driven Bevel Gear Slotted Nut [D]

○

Apply molybdenum disulfide oil to the seating surface of the driven bevel gear slotted nut, and tighten it.

Special Tools - Bevel Gear Holder: 57001-1638

Socket Wrench: 57001-1283

Torque - Driven Bevel Gear Slotted Nut: 118 N·m (12 kgf·m,

87 ft·lb)




•

Bend the tab [A] of toothed washer over the slotted nut

[B].

•

Install:

Shifter [A]

Driven Bevel Gear [B]

Collar [C]

•

Install:

Snap Ring [A]

Special Tool - Snap Ring Guide, 20 [B]: 57001-1633

○

Install the snap ring on the snap ring guide.

○

Cover the snap ring guide [A] on the driven bevel gear shaft [B], and slide the snap ring on the shaft.

○

Using the pipe (special tool), push the snap ring [C] in the groove [D] of the shaft.

•

Install:

Ball Bearing [A]



•

Apply grease to the oil seal lip, and install it.

•

Install:

Snap Ring [A]

Special Tool - Snap Ring Guide, 22 : 57001-1634

○

Install the snap ring on the cap [B] of the snap ring guide.

○

Slide the snap ring [A] until the ring gets to the body [B] of the snap ring guide.

○

Remove the cap from the body.


○

Cover the body [A] on the driven bevel gear shaft, and insert the snap ring [B] in the groove [C] of the shaft.

Drive Bevel Gear Removal

•

Remove:

Driven Bevel Gear Assembly (Driven Bevel Gear Removal)

•

Remove:

Rear Brake Panels (see Brakes chapter)

Rear Shock Absorbers (see Suspension chapter)

Left Rear Axle Bracket and Axle Shaft (see Rear Axle

Removal)

•

Install:

Bevel Gear Holder [A]

Special Tool - Bevel Gear Holder: 57001-1638

•

Set the “Differential Lock” position.

•

Remove:

Drive Bevel Gear Nut [B]

Washer

Drive Bevel Gear [C]

Shim




Drive Bevel Gear Installation

•

Check and adjust the bevel gear backlash when any of the backlash-related parts are replaced (see Bevel Gear

Adjustment).

•

Install:

Shim [A] (for Gear Backlash)

Drive Bevel Gear [B]

Washer [C] (take care the direction)

•

Apply molybdenum disulfide grease to the threads and seating surface of new drive bevel gear nut [D].

•

Face caulking side [E] to outward.

•

Tighten:


Torque - Drive Bevel Gear Nut: 137 N·m (14 kgf·m, 101 ft·lb)

Bevel Gear Adjustment

In order to prevent one gear from moving away from the other gear under load, the backlash 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. Adjust the backlash by replacing shims.

This adjustment is of critical importance and must be carried out in the correct sequence, using the procedures shown.



Backlash Adjustment

•

Check and adjust the gear backlash when any of the backlash-related parts are replaced with new ones.

•

Install:

Bevel Gear Holder [A] (see Drive Bevel Gear Removal)


•


•

Install:

Drive Bevel Gear (see Drive Bevel Gear Installation)

Driven Bevel Gear (see Driven Bevel Gear Installation)

Bevel Gear Holder [B]


•

Tighten:

Torque - Bevel Gear Case Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb)

•

Set up a dial gauge [C] against one of the teeth in the bevel gear [D].

•

To measure the backlash, while pushing the driven gear shaft to rearward and turn the shaft clockwise and counterclockwise while holding the drive bevel gear steady with the bevel gear holder. The difference between the highest and lowest gauge readings is the amount of backlash.

If the backlash is not within the limit, replace the shim(s) at the drive gear. To increase backlash, decrease the thickness of the shim(s). To decrease backlash, increase the thickness of the shim(s).


•

Recheck the backlash, and readjust as necessary.

Bevel Gear Backlash

Standard: 0.35

∼

0.50 mm (0.0138

∼

0.0197 in.)

(at driven bevel gear tooth)





Bevel Gear Case (Backlash-Related Parts)

1. Driven Gear Shaft

2. Ball Bearings

3. Drive Gear Shaft

4. Drive Gear Shim(s)

5. Drive Bevel Gear

6. Driven Bevel Gear

Drive Gear Shims [4]

Thickness

0.15 mm (0.0059 in.)

0.5 mm (0.0197 in.)

0.6 mm (0.0236 in.)

0.7 mm (0.028 in.)

0.8 mm (0.031 in.)

0.9 mm (0.035 in.)

1.0 mm (0.0039 in.)

1.1 mm (0.0043 in.)

1.2 mm (0.0047 in.)

Part Number

92025-1688

92025-1689

92025-1690

92025-1691

92025-1692

92025-1693

92025-1694

92025-1695

92025-1696



Bevel Gear Inspection

•

Visually check the drive bevel gear [A] and the driven bevel gear [B] for scoring, chipping, or other damage.

Replace the bevel gears as a set if either gear is damaged.

Ball Bearing/Oil Seal 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.

•



•

Inspect the oil seals.





Propeller Shafts (KAF400-A/C)

Front Propeller Shaft Removal

•

Remove:

Front Final Gear Case Guard (see Frame chapter)

Bottom Guard (see Frame chapter)

•

Slide the rubber boot [A] forward.

•

Push the universal joint [B] forward [C], and remove the rear end from the bearing housing.

•

Push the rear universal joint [A] forward fully, and remove the front propeller shaft [B] from the front universal joint.

Front Propeller Shaft Installation

•

When installing the cover [A], press the cover so that the cover surface is flush with the end of the yoke end.

○

Does not scratch the contact surface [B] of the oil seal.



•

Insert the propeller shaft [A] through the hole of the frame

[B].

•

Apply molybdenum disulfide grease to the spline [C] of the propeller shaft.

•

Apply grease to the oil seal lip [D].

•

Install:

O-rings [E]

Boot [F]

Spring [G]

Rear Universal Joint [H]

○

Refer to “Propeller Shafts Assembly” for universal joint installation.

•

Insert the propeller shaft into the front universal joint [I].

•

Push the rear universal joint forward fully, and install the propeller shaft rear end [J] on the bearing housing [K].

•

Install the O-rings [L] on the rubber boot.





Propeller Shafts Assembly

•

Install the each yokes [A] as the figure below.

Front Propeller Shaft [B]

Bearing Housing [C]

Rear Propeller Shaft [D]

Rear Propeller Shaft Removal

•

Remove:

Bottom Guard (see Frame chapter)

Front Propeller Shaft (see Front Propeller Shaft Removal)

•

Loosen the bearing housing bolts [A] as shown.

•

Remove:

Yoke Stop Bolt [A]



•

Push the universal joint [A] forward fully, and remove the rear end from the bevel gear shaft [B].

•

Remove:

Rear Propeller Shaft [C]


Rear Propeller Shaft Installation

•

When installing the cover [A], press the cover so that the distance between the cover surface and yoke end [B] is specified length [C] as sown.

[C] 0.9

∼

1.3 mm (0.012

∼

0.051 in.)

○

Does not scratch the contact surface [D] of the oil seal.

•

Apply molybdenum disulfide grease to the oil seal lip [A] and spline [B] of the bearing housing [C].

•

Install:

Spring [D]

•

Insert the front universal joint [E] into the bearing housing.

○

Refer to “Propeller Shafts Assembly” in the Front Propeller Shaft Installation for universal joint installation.

•

Push the propeller shaft [F] forward fully, and install the rear universal joint [G] on the bevel gear shaft [H].

•

Tighten:

Torque - Yoke Stop Bolt [I]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Bearing Housing Bolts [J]: 41.5 N·m (4.2 kgf·m, 31 ft·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.


Axles

Front Axle Removal (KAF400-A/C)

•

Remove:

Front Suspension Arm and Steering Knuckle (see Suspension chapter)

Front Axle [A]

○

Pull the axle straight.

Front Axle Installation (KAF400-A/C)

•

Wipe the old grease off the splines [A] of the axle and cap oil seal [B].

•

Visually inspect the splines of the axle.

If they are badly worn or chipped, replace the axle with a new one.

•

Apply molybdenum disulfide grease to the axle splines and oil seal.

•

Insert the axle and tap the end of the axle lightly, and install the axle.

NOTE

○

The axle shaft must not come off easily.

Front Axle Removal (KAF400-B)

•

Remove:

Front Wheel (see Wheels/Tires chapter)

Cotter Pin [A]


•

Remove:

Axle Nut [A]

Washer [B]

Front Axle [C]

Front Axle Installation (KAF400-B)

•

Tighten:

Torque - Front Axle Nuts: 147 N·m (15 kgf·m, 108 ft·lb)



Axles

Rear Axle Removal

•

Refer to Transmission Case Removal in the Transmission chapter for rear axle removal.

[A] Rear Right Axle

[B] Rear Left Axle

Rear Axle Installation

•

Refer to Transmission Case Installation in the Transmission chapter for rear axle installation.

•

Adjust:

Transmission Oil (see Transmission Oil Change in the

Periodic Maintenance chapter)

Axle Inspection

•

Visually inspect the splines of the axle.

If they are twisted, badly worn, or chipped, replace the axle with a new one.

•

Check that the ball joint works smoothly without rattling or sticking.

If it does not, the bearings of the joint are damaged. Replace the front axle with a new one.

Dust Boot Inspection (KAF400-A/C)

•

Visually inspect the boots [A] if the front axles are noisy during operation.

If the dust boot is torn, worn, or deteriorated, replace it.


Axles

Front Axle Joint Boot Replacement (KAF400-A/C)

Outboard Joint Boot Removal

•

Remove:

Front Axle (see Front Axle Removal)

Boot Bands [A]

•

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.

CAUTION

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]

Small Band [C]


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.

CAUTION

Only the special grease that is included with the boot kit can be applied to the boots.

•

Install:

New Circlip [C]



Axles

•

Apply the special grease slightly on the part [A] of the band installation in order to make easy to install the boot band.

•

Tighten the small boot band [B].

○

Tighten the boot band [A] and bend the tangs [B] securely to hold down the end of the band.

•

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.

•

Tap the shaft end [A] straight with a plastic hammer until it is locked by the circlip.

•

Squeeze all of the special grease [A] into the new boot

[B], and slide the boot onto the outboard joint [C].


Axles

•

Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling:

Outboard: 273.7 mm (10.78 in.) [A]

•

Open the edge of the boot in order to equalize the air pressures.

•

Tighten the large band [A] and bend the tangs securely to hold down the end of the band.

Maximum Outside Diameter of Band: 80.2 mm (3.16 in.)

(After tightening the outside diameter)

•

While the band is held at the diameter above, tap down the tangs [A] of the band.


Inboard Joint Boot Removal

•

Remove:

Front Axle (see Front Axle Removal)

Boot Bands [A]

•

Scrap the removed boot bands.

•

Slide the joint boot [B] toward the outboard joint.

•

Remove the retaining ring [A].

•

Separate to the axle shaft.



Axles

•

Remove the steel balls [A].

•

Slide the cage [B] toward the outboard joint.

•

Remove:

Circlip [A]


•

Remove:

Inner Race [A]

Cage [B]

Inboard Joint Boot [C]

Boot Band [D]

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 side [B] faces outboard joint.


Axles

•

Install:

Circlip [A]


•

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.


•

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.

•

Install the new retaining ring [A] so that the opening [B] is aligned with one of the projections [C].



Axles

•

Tighten the small band.

•

Squeeze the remaining special grease [A] into the inboard joint boot [B].

•

Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling:

Inboard: 173.5 mm (6.83 in.) [A]

•

Open the edge of the boot in order to eqalize the air pressures.

•

Tighten the large band [A].

○

Assemble it the same as the outboard joint boot, noting this setting;

Maximum Outside Diameter of Band: 75.7 mm (2.98 in.)

(After tightening the outside diameter)

•

While the band is held at the diameter above, tap down the tangs [A] of the band.


•

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.

•




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.




BRAKES 12-1

Brakes


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Brake Fluid ............................................................................................................................

Brake Fluid Recommendation...........................................................................................

Brake Fluid Level Inspection ............................................................................................

Brake Fluid Change ..........................................................................................................

Brake Line Air Bleeding ...................................................................................................

Brake Pedal and Master Cylinder ..........................................................................................

12-10

Brake Pedal Play Inspection .............................................................................................

12-10

Master Cylinder Removal..................................................................................................

12-10

Master Cylinder Installation...............................................................................................

12-10

Master Cylinder Disassembly/Assembly...........................................................................

12-10

Master Cylinder Inspection ..............................................................................................

12-11

Brake Hoses and Pipes ..........................................................................................................

12-12

Brake Hose and Pipe Inspection.......................................................................................

12-12

12-2

12-6

12-7

12-8

12-8

12-8

12-8

12-8

Brake Hose and Pipe Replacement..................................................................................

12-12

Brake Drums...........................................................................................................................

12-13

Brake Drum Removal........................................................................................................

12-13

Brake Drum Installation.....................................................................................................

12-13

Brake Drum Wear .............................................................................................................

12-14

Brake Panel Assemblies.........................................................................................................

12-15

Brake Panel Assy Removal ..............................................................................................

12-15

Brake Panel Assy Installation ...........................................................................................

12-15

Brake Panel Disassembly .................................................................................................

12-16

Brake Panel Assembly......................................................................................................

12-18

Wheel Cylinder Removal/Installation ................................................................................

12-20

Wheel Cylinder Assembly .................................................................................................

12-20

Wheel Cylinder Inspection ................................................................................................

12-20

Brake Shoe Lining Wear ...................................................................................................

12-20

Brake Shoe Spring Inspection ..........................................................................................

12-21

Grease Seal Replacement................................................................................................

12-21

Parking Brake Lever and Cables............................................................................................

12-22

Parking Brake Lever Travel Adjustment ..........................................................................

12-22

Parking Brake Cable Lubrication/Inspection .....................................................................

12-22

12


12-2 BRAKES

Exploded View

Front Brake


BRAKES 12-3

Exploded View

No.

Fastener

1 Push Rod Locknut

2 Master Cylinder Reservoir Cap

3 Reservoir Clamp Bolt

4 Master Cylinder Mounting Bolts

5 Piston Stop Bolt

6 Brake Pipe Nipples

7 Brake Hose Banjo Bolts

8 Parking Lever Mounting Bolts

9 Bleed Valves

10 Wheel Cylinder Mounting Bolts

11 Breather Fitting

12 Front Brake Panel Mounting Bolts

13 Front Axle Nuts

N·m

18

3.4

6.2

22.5

8.8

1.8

25

22.5

8.0

12

6.0

34

147

14. Grease Seal (KAF400-A/C)

AG: Apply grease (Amoco rykon premium grease No.2 EP Green).

G: Apply grease.



Torque kgf·m

1.8

0.35

0.63

2.3

0.90

1.8

2.5

2.3

0.82

1.2

0.61

3.5

15

ft·lb

13

30 in·lb

55 in·lb

17

78 in·lb

13

18

17

71 in·lb

106 in·lb

53 in·lb

25

108

Remarks

L


12-4 BRAKES

Exploded View

Rear Brake


Exploded View

No.

1 Brake Pipe Nipples

2 Brake Pipe Mounting Bolt

3

4

Bleed Valves

Fastener


5 Breather Fitting

6 Rear Brake Panel Mounting Bolts

N·m

18

22.5

8.0

12

6.0

34

Torque kgf·m

1.8

2.3

0.82

0.2

0.61

3.5

7 Rear Axle Nuts 304 31

8. Grease Seal (KAF400-A/C)

AG: Apply grease (Amoco rykon premium grease No.2 EP Green).



ft·lb

13

17

71 in·lb

106 in·lb

53 in·lb

25

224

BRAKES 12-5

Remarks

L


12-6 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

∼

5 mm (0.08

∼

0.20 in.)

165.00

∼

165.16 mm (6.4961

∼

6.5023 in.)

Brake Panel Assemblies

Brake Shoe Lining Thickness

Parking Brake Lever And Cables

Parking Brake Lever Travel

4 mm (0.16 in.)

8

∼

12 notches (clicks)

Service Limit

– – –

– – –

– – –

165.75 mm

(6.526 in.)

1 mm (0.04 in.)

– – –


Special Tools

Clutch Spring Compressor:

57001-1162

Rotor Puller, M16/M18/M20/M22 × 1.5:

57001-1216

Brake Drum Holder:

57001-1325

Brake Drum Remover:

57001-1260

Gear Seal Driver Set:

57001-1629

BRAKES 12-7

Brake Drum Pusher, M18 × 1.5:

57001-1261


12-8 BRAKES

Brake Fluid

Brake Fluid Recommendation

•

Use extra heavy-duty brake fluid only from a container marked DOT3.

Recommended Brake Fluid

Type: DOT3

WARNING

Never reuse old brake fluid.

Do not use fluid from a container that has been left unsealed or that has been open for a long time.

Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

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.

CAUTION


Brake Fluid Level Inspection

•

Refer to the Brakes in the Periodic Maintenance chapter.

Brake Fluid Change

•


Brake Line Air Bleeding

•


•

Remove:

Rubber Cap

Brake Fluid Reservoir Cap

•

Level the reservoir [A] 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 Wheels/Tires chapter).

•

Connect a clear plastic hose [A] to the bleed valve at the wheel cylinder, running the other end of the hose into a container.

[B] Brake Panel

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 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: 8.0 N·m (0.82 kgf·m, 71 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.

•


Torque - Master Cylinder Reservoir Cap: 3.4 N·m (0.35


BRAKES 12-9


12-10 BRAKES

Brake Pedal and Master Cylinder

Brake Pedal Play Inspection

•


Master Cylinder Removal

•

Remove:


Cotter Pin [A] and Pin [B]

Brake Hose Banjo Bolts [C]

Brake Pipe Nipple [D] (unscrew)

•


CAUTION


•

Remove:

Master Cylinder Mounting Bolts [E] and Master Cylinder

[F]

Master Cylinder Installation

•

Use a new flat washer on each side of the brake hose fitting.

•

Apply brake fluid to the brake pipe nipple threads.

•

Tighten:

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

Brake Pipe Nipple: 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 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 primary 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 12-11


12-12 BRAKES

Brake Hoses and Pipes

Brake Hose and Pipe Inspection

•


Brake Hose and Pipe Replacement

•



BRAKES 12-13

Brake Drums

Brake Drum Removal

•

Remove:

Wheel (see Wheels/Tires chapter.)

Cotter Pin [A]

Axle Nut [B] and Washer

○

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: 5700-1325

•

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

•

Hold the brake drum remover and tighten the rotor puller.

•

Remove:

Brake Drum

Brake Drum Installation

•

Grease (Amoco Rykon Premium Grease No.2 EP Green) the brake drum grease seal lips [A] and inside [B] of the drum as shown.

Grease Seal (KAF400-A/C models) [C]

Brake Drum [D]

•

Install:

Brake Drum

•

Mount the brake drum holder [A] securely on the drum studs with the wheel nuts.

Special Tool - Brake Drum Holder: 57001-1325

•

For front brake drum, 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: 147 N·m (15 kgf·m, 108 ft·lb)

•

For rear brake drum, install the washer and axle nut.

•

Tighten:

Torque - Rear Axle Nuts: 304 N·m (31 kgf·m, 224 ft·lb)


12-14 BRAKES

Brake Drums

•

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 degree.

○

Loosen once and tighten again when the slot goes past the nearest hole.

•

Bend the cotter pin [A] over the nut.

WARNING

If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result.

Brake Drum Wear

•




Brake Panel Assy Removal

•

Remove:

Brake Drum (see Brake Drum Removal)

Breather Hose

Brake Pipe Nipple [A] and Brake Pipe [B]

Clip (for Front Brake Panel)

•


CAUTION


•

Remove (for Rear Brake Panel):

Left Side Cover (see Frame chapter)

Parking Brake Cable End(s) [A]

Rear Brake Drum (see Brake Drum Removal)

•

Remove

Collar

Brake Panel Mounting Bolts [A]

Brake Panel Assembly [B]

Brake Panel Assy Installation

(for Front Brake Panel)

•

Clean the mating surface of the brake panel and steering knuckle.

•

Apply liquid gasket to the mating surface [A] of the steering knuckle (except bolt holes).

Sealant Three Bond 1215 Gray

BRAKES 12-15


12-16 BRAKES


(for Rear Brake Panel)

•

Clean the mating surface of the brake panel and drive shaft bracket.

•

Apply liquid gasket to the mating surface [A] of the drive shaft bracket (except bolt holes).

Sealant Three Bond 1215 Gray

•

Install:

Brake Panel Assembly

Collar

○

For rear collar installation, face the stepped side [A] to inside [B].

•

Apply a non-permanent locking agent to the brake panel mounting bolts.

Bond Loctite 242 Blue

•

Tighten:

Torque - Brake Panel Mounting Bolts: 34 N·m (3.5 kgf·m,

25 ft·lb)

•

Install:

Parking Brake Cable End(s) (for Rear Brake Panel)

•

Bleed the brake line after brake drum installation (see

Brake Line Air Bleeding in this chapter).

•

Be sure to check the brake system for good braking power, no brake drag, and no fluid leakage.

WARNING


•

Adjust:

Parking Brake Lever Inspection (see Parking Brake

Lever Inspection in the Periodic Maintenance chapter).

Brake Panel Disassembly

•

Remove:

Brake Drum (see Brake Drum Removal)

Brake Pipe Nipple [A] and Brake Pipe [B] (If the brake panel or wheel cylinder are removed.)

•


CAUTION




•

Using a suitable tool, remove the brake shoe spring [A].

BRAKES 12-17

•

While pushing the shoe hold-down spring [A], turn the pin

[B] 90° and remove the spring.

•

Remove:

Shoe [A]

Shoe Spring [B]

Parking Brake Lever Linkage [C]

NOTE

○

Wrap the brake shoes with a clean cloth to protect the linings from grease or dirt.

•

While pushing the shoe hold-down spring [A], turn the pin

[B] 90° and remove the spring

•

Remove:

Shoe [C]

•

Remove (for Rear Brake Panel):

Parking Brake Cable End(s)

○

Hold the bolt [A] and loosen the nut.

CAUTION

Do not turn the bolt. The bolt is engaged by the spline in the brake panel. When removing the cable, loosen the nut only.

○

Remove:

Parking Brake Cable Bracket [B]

Parking Brake Cable


12-18 BRAKES


Brake Panel Assembly

•

Install (for Rear Brake Panel):

New Gasket [A]

•

Install (for Rear Brake Panel):

Parking Brake Cable

Parking Brake Cable Bracket [A]

Parking Brake Cable Bracket Nut [B]

○

Hold the bolt [C] and tighten the nut.

CAUTION

Do not turn the bolt. The bolt is engaged by the spline in the brake panel. When installing the cable, tighten the nut only.

•

Apply high-temperature grease:

Contact Points [A] of Brake Panel and Brake Shoes

•

Install:

Shoe [A]

•

While pushing the shoe hold-down spring [B], turn the pin

[C] 90° and install the spring.

•

Install:

Linkage Springs [A]

Parking Brake Lever Linkage [B]

Shoe Spring [C]



•

Install:

Shoe [A]

•

Install:

Shoe [A]

•

While pushing the shoe hold-down spring [B], turn the pin

[C] 90° and install the spring.

•

Pry the ratchet lever [A] with a screwdriver [B] to reset the shoe clearance adjuster in its original position.

BRAKES 12-19

[A] Original Position of Ratchet Lever

[B] Ratchet Lever

•

Apply liquid gasket to around [A] of shoe hold-down spring pin heads.

•

Install:

Brake Pipe and Brake Pipe Nipple [B]

•

Tighten:

Torque - Brake Pipe Nipple: 18 N·m (1.8 kgf·m, 13 ft·lb)

•

Install:

Brake Drum (see Brake Drum Installation)


12-20 BRAKES


•

Bleed the brake line (see Brake Line Air Bleeding).

•

Be sure to check the brake system for good braking power, no brake drag and no fluid leakage.

WARNING


•

Inspect and if necessary adjust:

Parking Brake Lever Inspection (see Parking Brake

Lever Inspection in the Periodic Maintenance chapter)

Wheel Cylinder Removal/Installation

•

Refer to 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.

CAUTION

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

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 [A] and on the outside of the piston

[B].

If the cylinder or piston shows any damage, replace the wheel cylinder.

•

Inspect the cups [C].

If a cup is worn, damaged, softened (rotted) or swollen, replace the wheel cylinder.

If fluid leakage is noted at the dust seals, the wheel cylinder should be replaced to renew the cup.

•

Check the dust seals [D] for damage.

If they are damaged, replace the wheel cylinder.

•

Check the spring [E] for any damage.

If the spring is damaged, replace the wheel cylinder.

Brake Shoe Lining Wear

•

Refer to Brake Wear Inspection in the Periodic Maintenance chapter.


BRAKES 12-21


Brake Shoe Spring Inspection

•

Visually inspect the brake shoe springs [A] and linkage springs [B] for breaks or distortion.

If the springs are damaged in any way, replace them.

Grease Seal Replacement

•

Remove:

Brake Panel Assembly (see Brake Panel Assy Removal)

Bleed Valve

Breather Fitting

Grease Seal [A]

CAUTION

Be careful not to damage the brake panel when removing the grease seal.

Do not remove the cable bracket bolt [B].

•

Install the grease seal [A] to specified position as shown.

Top Surface of Grease Seal [B]

Center Bottom of Brake Panel [C]

6.2

∼

7.0 mm (0.24

∼

0.27 in.) [D]

NOTE

○

If the following special tool (Grease Seal Driver Set) is used, the position will be secured.

•

Apply rubber lubricant oil to inside area of the new grease seal.

•

Put the brake panel [A] on the flat plate [B] so that the cable bracket bolt [C] is not contact to the plate.

•

Put the guide [D] in the panel.

Special Tool - Grease Seal Driver Set: 57001-1629

•

Put the grease seal [E] 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.

•

Grease (Amoco Rykon Premium Grease No.2 EP Green) the grease seal lips (see Brake Drum Installation).

•

Tighten:

Torque - Bleed Valve: 8.0 N·m (0.82 kgf·m, 71 in·lb)

Breather Fitting: 6.0 N·m (0.61 kgf·m, 53 in·lb)


12-22 BRAKES

Parking Brake Lever and Cables

Parking Brake Lever Travel Adjustment

•


Parking Brake Cable Lubrication/Inspection

•



SUSPENSION 13-1

Suspension


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tool ............................................................................................................................

Struts and Rear Shock Absorbers ..........................................................................................

Strut (Front Shock Absorber) Removal.............................................................................

Strut (Front Shock Absorber) Installation..........................................................................

Rear Shock Absorber Preload Adjustment .......................................................................

Rear Shock Absorber Removal ........................................................................................

Rear Shock Absorber Installation .....................................................................................

Rear Shock Absorber Inspection ......................................................................................

Front Suspension Arms ..........................................................................................................

13-7

13-7

13-8

13-9

Front Suspension Arm Removal .......................................................................................

13-9

Front Suspension Arm Installation ....................................................................................

13-10

Front Suspension Arm Inspection.....................................................................................

13-10

Swingarm................................................................................................................................

13-11

13-2

13-4

13-5

13-6

13-6

13-6

13-7

Swingarm Removal...........................................................................................................

13-11

Swingarm Installation........................................................................................................

13-11

Swingarm Inspection.........................................................................................................

13-12

Swingarm Joint Replacement ...........................................................................................

13-12

13


13-2 SUSPENSION

Exploded View


Exploded View

No.

Fastener

1 Strut Mounting Nuts

2 Strut Clamp Nuts

3 Front Suspension Arm Pivot Bolts

4 Front Suspension Arm Joint Nuts

5 Swingarm Joint Nut

6 Swingarm Rod Bolts

7 Rear shock Absorber Mounting Nuts


SUSPENSION 13-3

N·m

44

98

88.2

78.5

54

50

54

Torque kgf·m

4.5

10

9.0

8.0

5.5

5.1

5.5

ft·lb

32

72

65

58

40

37

40

Remarks


13-4 SUSPENSION

Specifications

Item

Rear Shock Absorbers

Spring preload setting position

Standard

3rd position

Service Limit

(Usable Range)

1

∼

5 positions


Special Tool


57001-144

Steering Stem Nut Wrench:

57001-1100

SUSPENSION 13-5


13-6 SUSPENSION

Struts and Rear Shock Absorbers

Strut (Front Shock Absorber) Removal

•

Remove:



Brake Panel Assembly (see Brakes chapter)

Tie-rod End [A] (see Knuckle Removal in the Steering chapter)

•

Remove:

Totter Pin [A]

Strut Clamp Bolt and Nut [B]

•

Remove:

Suspension Arm Bolts [A]

Suspension Arm with Steering Knuckle [B]

•

Remove:

Strut Mounting Nuts [A]

Strut

Strut (Front Shock Absorber) Installation

•

Insert the strut into the steering knuckle [A] while aligning the notch [B] on the strut with the clamp bolt hole [C] on the steering knuckle.

•

Tighten:

Torque - Strut Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb)

Strut Clamp Nut: 98 N·m (10 kgf·m, 72 ft·lb)



•

Insert a new cotter pin [A] through the clamp bolt and bend it over the nut.

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the bolt, tighten the nut clockwise up to next alignment.

○


○

Loosen once and tighten again when the slit goes past the nearest hole.

•

Install the removed parts (see appropriate chapter).

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

2

3 (STD)

4

5

↓

Setting

Soft

↑

↓

Stronger Hard

Load

Light

↑

↓

Heavy

Terrain Speed

Smooth

↑

↓

Rough

Low

↑

↓

High

•

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 adjusting sleeves are not adjusted equally, handling may be impaired and a hazardous condition may result.

Rear Shock Absorber Removal

•

Remove:

Rear Wheel (see Wheels/Tires chapter)

•

Remove:

Rear Shock Absorber Mounting Bolts and Nuts [A] (while moving the frame up or down with a jack)

Rear Shock Absorber [B]

Rear Shock Absorber Installation

•

Install the rear wheel temporarily and ground it to load the suspension.

•

Tighten:

Torque - Rear Shock Absorber Mounting Nuts: 54 N·m (5.5

SUSPENSION 13-7

13-8 SUSPENSION


Rear 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 [A] 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:



Brake Panel Assembly (see Brakes chapter)

Tie-rod End [A] (see Knuckle Removal in the Steering chapter)

•

Remove:

Cotter Pin [A]

Strut Clamp Bolt and Nut [B]

SUSPENSION 13-9

•

Remove:

Suspension Arm Bolts [A]

Front Suspension Arm Joint Nut [B]

Suspension Arm with Steering Knuckle [C]

•

Install a suitable nut [A] on the stud of the joint end and tap the nut to free the joint from the suspension arm [B].


13-10 SUSPENSION

Front Suspension Arms

Front Suspension Arm Installation

•

Clean the sealing surface and the tapered portion of the steering knuckle joint and the tapered hole of the front suspension arm, or the tapers will not fit snugly.

•

Install:

Front Suspension Arm Joint Boot Sealing Surface [A]

Good [B] Bad [C]

•

When the front suspension arm pivot bolts are tightened, install the arm joint in the steering knuckle to position the arm within its operating angle.

•

Tighten:

Torque - Front Suspension Arm Pivot Bolts: 88.2 N·m (9.0


Front Suspension Arm Joint Nut: 78.5 N·m (8.0


•

Insert a new cotter pin [A] through the arm joint and bend it over the nut.

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the joint, tighten the nut clockwise up to next alignment.

○


○


Front Suspension Arm Inspection

•

Visually inspect the front suspension arm [A] for breaks or distortion.

If the front suspension arm is damaged in any way, replace it.

•

Check the rubber bushings [B] in the pivots.

Replace any bushings that are worn, cracked, hardened, or otherwise damaged.


SUSPENSION 13-11

Swingarm

Swingarm Removal

•

Remove:


Transmission Case (see Transmission chapter)

Engine (see Engine Removal/Installation chapter)

Brake Pipes [A] (see Brakes chapter)

Retainer [B]

•

Remove:

Bolt [A] and Nut

Swingarm Rod [B]

•

Remove:

Bolt [A] and Connecting Wire [B]

Cotter Pin [C]

Nut [D] and Washer

•

Install a suitable nut [A] on the swingarm joint [B] and tap the nut to free the joint from the frame [C].

•

Remove:

Swingarm [D]

Swingarm Installation

○

When install the rubber bushings [A] in the swingarm rod

[B], lubricate them with a soap and water solution

CAUTION

Do not use engine oil or petroleum distillates to lubricate the bushings because they will deteriorate the rubber.


13-12 SUSPENSION

Swingarm

•

Clean the sealing surface and the taper surface [A] of the frame bracket and shank [B] of the swingarm joint, or the tapers will not fit snugly.

•

Install:

Swingarm Joint Nut and Washer

Swingarm Rod Bolt and Nut

•

Tighten:

Torque - Swingarm Joint Nut: 55 N·m (5.5 kgf·m, 40 ft·lb)

Swingarm Rod Bolt: 50 N·m (5.1 kgf·m, 37 ft·lb)

•

Install:

Bolt and Connecting Wire

Swingarm Inspection

•

Visually inspect the swingarm [A] for breaks or distortion.

If the swingarm is damaged in any way, replace it.

•

Visually inspect the rubber bushings [A] in the swingarm rod [B].

If they are worn, cracked, hardened, or otherwise damaged, replace them with new ones.

Swingarm Joint Replacement

•

Remove:

Swingarm (see Swingarm Removal)

Circlip [A]


○

Using a press, remove the swingarm joint [C].

•

Replace:

Swingarm Joint

Circlip

•

Using a press, install the swingarm joint.

•

Install:

Circlip



STEERING 14-1

Steering


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Steering Wheel and Main Shaft Assembly .............................................................................

Steering Wheel Free Play Inspection................................................................................

Steering Wheel Centering.................................................................................................

Steering Wheel and Steering Shaft Removal ...................................................................

Steering Wheel and Steering Shaft Installation ................................................................

Steering Gear Assembly.........................................................................................................

Steering Gear Assembly Removal....................................................................................

Steering Gear Assembly Installation.................................................................................

Steering Gear Preload Adjustment ...................................................................................

Tie-rod Length Adjustment................................................................................................

Dust Boot Inspection.........................................................................................................

14-9

14-9

14-9

Steering Knuckles...................................................................................................................

14-10

Steering Knuckle Removal................................................................................................

14-10

Steering Knuckle Installation.............................................................................................

14-10

Knuckle Bearing Removal.................................................................................................

14-11

Knuckle Bearing Installation..............................................................................................

14-11

Knuckle Joint Removal .....................................................................................................

14-11

Knuckle Joint Installation ..................................................................................................

14-12

14-2

14-4

14-5

14-6

14-6

14-6

14-6

14-7

14-8

14-8

14-8

14


14-2 STEERING

Exploded View


Exploded View

No.

Fastener

1 Steering Wheel Mounting Nut

2 Main Shaft Mounting Bolts

3 Intermediate Shaft Clamp Bolts

4 Steering Gear Assembly Bracket Bolts

5 Rack Guide Spring Cap Locknut

6 Tie-rod Locknuts

7 Strut Clamp Nuts

8 Tie-rod End Nuts

9. Horn Switch (Europe Model)

10. Horn Switch Contact (Europe Model)

G: Apply grease.


STEERING 14-3

N·m

54

34

25

54

39

44

98

34

Torque kgf·m

5.5

3.5

2.5

5.5

4.0

4.5

10

3.5

ft·lb

40

25

18

40

29

32

72

25

Remarks


14-4 STEERING

Specifications

Item

Steering Wheel

Steering Wheel Free Play

Steering Gear Assembly

Tie-Rod Length

(Distance Between Flange End and Locknut)

Standard

0

∼

20 mm (0

∼

0.79 in.) about 34 mm (1.34 in.)

Service Limit

– – –

– – –


Special Tools

Inside Circlip Pliers:

57001-143


57001-144


57001-1129

Knuckle Joint Remover:

57001-1619

STEERING 14-5

Knuckle Joint Driver:

57001-1640


14-6 STEERING

Steering Wheel and Main Shaft Assembly

Steering Wheel Free Play Inspection

•

Refer to 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 (see

Wheels/Tires chapter).

•

Remove the cap [A] and the horn switch (Europe model), and then loosen the steering wheel mounting nut [B].

•

Push the vehicle in a straight line with no one aboard, and stop it without turning the steering wheel.

•

Remount the steering wheel [C] so that it is straight ahead.

Torque - Steering Wheel Mounting Nut: 54 N·m (5.5 kgf·m,

40 ft·lb)

Steering Wheel and Steering Shaft Removal

•

Remove (see above):


Wheel Cap and Horn Switch (Europe model)

Steering Wheel Mounting Nut and Spring Washer

Steering Wheel

•

Remove (Europe model):

Screws and Horn Switch Contact

Two Straps of Horn Switch Body Lead

•

Remove:

Main Shaft Mounting Bolts, Washers and Nuts [A]

Main Shaft Clamp Bolt [B]

•

Lift the main shaft [C].

•

Remove:

Steering Gear Shaft Clamp Bolt [A]

•

Lift the intermediate shaft [B].


Steering Wheel and Main Shaft Assembly

Steering Wheel and Steering Shaft Installation

•

Grease:

Dust Cover Lips [A]

•

Connect the intermediate shaft [A] to the main shaft [B] with the steering gear pinion in any position.

•

Mount the steering wheel on the main shaft temporarily.

•

Adjust:

Steering Wheel Position Adjustment

Steering Wheel Centering

•

Tighten:

Torque - Intermediate Shaft Clamp Bolts [C]: 25 N·m (2.5


Steering Wheel Mounting Nut: 54 N·m (5.5 kgf·m,

40 ft·lb)

(Europe model)

•

Install the horn switch [A] as shown.

STEERING 14-7


14-8 STEERING


Steering Gear Assembly Removal

•

Remove:


Front Wheels (see Wheels/Tires chapter)

Steering Wheel and Steering Shaft (see Steering Wheel and Steering Shaft Removal)

Cotter Pins, Tie-rod End Nuts [A] and Tie-rod Ends [B] from Steering Knuckles

○

Install a suitable nut on the stud of the tie-rod end joint and tap the nut to free the joint from the steering knuckle.

CAUTION

Do not loosen the tie-rod end locknuts [C], or the toe-in of the front wheels will be changed.

•

Remove (front view):

Screw [A] and Horn Ground Lead Terminal

Steering Gear Assembly Bracket Bolts [B] and Brackets

[C]

•

Remove:

Steering Gear Assembly [A]

Steering Gear Assembly Installation

•

Adjust if necessary:

Steering Gear Preload Adjustment

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.

•

Grease:

Tie-rod End Joint Boot Sealing Surfaces [A]

[B] Good

[C] Bad

•

Tighten:

Torque - Steering Gear Assembly Bracket Bolts: 54 N·m

(5.5 kgf·m, 40 ft·lb)

Tie-rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)

○

Tighten the steering gear assembly bracket bolts evenly.

•

Check:

Toe-in of Front Wheels (see Wheels/Tires chapter)



Steering Gear Preload Adjustment

•

Loosen the locknut [A].

•

Tighten the rack guide spring cap [B] to 12.3 N·m (1.3

kgf·m, 109 in·lb) of torque.

•

Back off the cap 60

∼

70°.

•

Tighten the locknut while preventing the cap from turning.

Torque - Rack Guide Spring Cap Locknut: 39 N·m (4.0


Pinion [C]

Rack [D]

Rack Guide [E]

Spring [F]

Top [G]

Tie-rod Length Adjustment

•

Refer to Toe-in Adjustment in the Wheels/Tires chapter.

Tie-rod Length [A]

Dust Boot Inspection

•

Refer to the Steering in the Periodic Maintenance chapter.

STEERING 14-9


14-10 STEERING

Steering Knuckles

Steering Knuckle Removal

•

Remove the steering knuckle together with the front suspension arm (see Front Suspension Arm Removal in the

Suspension chapter).

•

Install a suitable nut [A] on the stud of the tie-rod end joint [B] and tap the nut to free the joint from the steering knuckle [C].

○

The steering knuckle comes off the front suspension arm

[D].

Steering Knuckle Installation

•

Clean the sealing surface and the tapered portions [A] 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, or the tapers will not fit snugly.

•

Grease:

Front Suspension Arm Joint Boot Sealing Surfaces [A]

[B] Good

[C] Bad

•

Tighten:

Torque - Strut Clamp Nuts: 98 N·m (10 kgf·m, 72 ft·lb)

Front Suspension Arm Joint Nut: 78.5 N·m (8.0


Tie-rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)

•

Insert a new cotter pin [A] through the clamp bolt or joint and bend it over the nut.

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the clamp bolt or joint, tighten the nut clockwise up to next alignment.

○


○


•


•

Check:

Toe-in of Front Wheels (see Wheels/Tires chapter)



Knuckle Bearing Removal

•

Remove:

Steering Knuckle (see Steering Knuckle Removal)

Circlip [A]

Special Tool - Inside Circlip Pliers [B]: 57001-143

•

Drive the bearing [A] out using a suitable bearing driver in the bearing driver set.


Knuckle Bearing Installation

•

Press in the bearing until it is bottomed.


•

Replace the circlip with a new one.

Special Tool - Inside Circlip Pliers: 57001-143

Knuckle Joint Removal

•

Remove:

Steering Knuckle (see Steering Knuckle Removal)

Circlip [A]


•

Remove the knuckle joint [A] using a press.

Special Tool - Knuckle Joint Remover [B]: 57001-1619

STEERING 14-11


14-12 STEERING


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.



FRAME 15-1

Frame


Exploded View........................................................................................................................

Seat and Seat Belts................................................................................................................

Seat Removal ...................................................................................................................

Seat Installation ................................................................................................................

Seat Belt Removal ............................................................................................................

Seat Belt Installation .........................................................................................................

Control Panel..........................................................................................................................

Control Panel Removal .....................................................................................................

Glove Compartment Removal...........................................................................................

15-10

Front Cargo Compartment......................................................................................................

15-11

Front Cargo Hood Removal ..............................................................................................

15-11

Front Cargo Compartment Removal.................................................................................

15-11

Front Cargo Compartment Installation..............................................................................

15-12

Cargo Bed ..............................................................................................................................

15-13

Cargo Bed Removal..........................................................................................................

15-13

Cargo Bed Assembly ........................................................................................................

15-14

15-2

15-8

15-8

15-8

15-8

15-8

15-9

15-9

Cargo Bed Installation.......................................................................................................

15-14

Cargo Bed Latch Position Inspection................................................................................

15-15

Cargo Bed Latch Position Adjustment ..............................................................................

15-15

Front and Rear Bars ...............................................................................................................

15-16

Front Bar Removal............................................................................................................

15-16

Front Bar Installation.........................................................................................................

15-16

Rear Bar Removal ............................................................................................................

15-16

Rear Bar Installation .........................................................................................................

15-16

Front Fender...........................................................................................................................

15-17

Front Fender Installation ...................................................................................................

15-17

Guard and Cover ....................................................................................................................

15-18

Front Guard Removal .......................................................................................................

15-18

Front Guard Installation ....................................................................................................

15-18

Floor Center Panel Removal.............................................................................................

15-18

Floor Center Panel Installation..........................................................................................

15-19

Front Final Gear Case Guard Removal ............................................................................

15-19

Front Final Gear Case Guard Installation .........................................................................

15-19

Bottom Guard Removal ....................................................................................................

15-19

Bottom Guard Installation .................................................................................................

15-20

Transmission Case Guard Removal .................................................................................

15-20

Transmission Case Guard Installation ..............................................................................

15-20

Center Cover Removal .....................................................................................................

15-20

Center Cover Installation ..................................................................................................

15-20

Side Covers Removal .......................................................................................................

15-21

Side Covers Installation ....................................................................................................

15-21

Guard Plate Removal........................................................................................................

15-21

Guard Plate Installation.....................................................................................................

15-22

15


15-2 FRAME

Exploded View


Exploded View

AD: Apply adhesive agent.

G: Apply grease.

FRAME 15-3


15-4 FRAME

Exploded View


FRAME 15-5

Exploded View

No.

Fastener

1 Front Bar Mounting Bolts (Lower)

2 Front Bar Mounting Bolts (Upper)

3 Rear Bar Mounting Bolts (L=20 mm)

4 Rear Bar Mounting Bolts (L=16 mm)

5 Seat Belt Mounting Bolts

6. Dampers


G: Apply grease.

N·m

98

44

44

44

34

Torque kgf·m

10

4.5

4.5

4.5

3.5

ft·lb

72

32

32

32

25

Remarks


15-6 FRAME

Exploded View


Exploded View


G: Apply grease.

L: Apply Locktite 242 Blue.

FRAME 15-7


15-8 FRAME

Seat and Seat Belts

Seat Removal

•

Remove:

Seat Bracket Nuts [A]

Seat Brackets [B]

Seat [C]

•

Remove:

Seat Back Mounting Nuts [A]

Seat Back [B]

Seat Installation

•

Grease:

Seat Bracket Inside Surfaces [A]

•

Touch the bracket [B] to the stopper [C] on the frame.

•

Tighten each nut.

Seat Belt Removal

•

Remove:

Seat Belt Mounting Bolts [A]

Seat Belts [B]

Seat Belt Buckles [C]

Seat Belt Installation

•

Tighten:

Torque - Seat Belt Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)


Control Panel

Control Panel Removal

•

Remove:

Front Cargo Compartment (see Front Cargo Compartment Removal)

•

Disconnect:

Ignition Switch Lead Connector [A]

Power Outlet Connector Lead Connectors [B]

•

Disconnect:

Hour Meter Lead Connector [A]

Oil Temperature Warning Indicator Light Lead Connectors [B]

Parking Brake Indicator Light Lead Connector [C]

Light Switch Lead Connector [D]

•

Remove:

Snap Pins [A] and Pins

Glove Compartment Cover [B]

•

Remove:

Control Panel Screws [A] and Collars

Control Panel [B]

FRAME 15-9


15-10 FRAME

Control Panel

Glove Compartment Removal

•

Remove:

Control Panel (see Control Panel Removal)

Screws [A]

Glove Compartment [B]


FRAME 15-11

Front Cargo Compartment

Front Cargo Hood Removal

•

Remove:

Snap Pins [A]

Washer [B]

Mounting Pins [C]

Lever

•

Remove:

Snap Pin [A]

Mounting Pin [B]

Front Cargo Hood [C]

Front Cargo Compartment Removal

•

Remove:

Screws [A] and Collars

•

Remove:


•

Remove:


Quick Rivet [B]


15-12 FRAME

Front Cargo Compartment

•

Remove:

Quick Rivet [A]

Front Cargo Compartment [B]

Front Cargo Compartment Installation

•

Install:

Screws (6 × 16 mm, 0.24 × 0.63 in.) [A]

Collars (6 mm, 0.24 in.) [B]

Screws (6 × 2 mm, 0.24 × 0.08 in.) [C]

Washers [D]

Well Nuts [E]

Quick Rivets [F]

Collars (4 mm, 0.16 in.) [G]


FRAME 15-13

Cargo Bed

Cargo Bed Removal

•

Remove:

Hook [A] (unlock)

•

Remove:

Rear Fender Mounting Screws [A] and Collars

•

Remove:

Rear Fender Mounting Screw [A]

Rear Fenders [B]

•

Remove:

Tail/Brake Light Lead Connectors [A]

Tail/Brake Light Mounting Bolts [B]

Tail/Brake Light Assembly [C]

•

Remove:

Snap Pins [A]

Cargo Bed Mounting Pins [B]

Cargo Bed [C]


15-14 FRAME

Cargo Bed

Cargo Bed Assembly

•

Install:

Insulators [A]

Supporting Hook [B]

Bolt [C] and Nut [D]

Supporting Hook Holder [E]

Screw [F]

•

Apply grease to the outside of the latch shaft [A].

•

Apply grease to the inside of the pipe [B].

•

Apply adhesive LOCKTITE 242 to the latch handle [C].

•

Install:

Latch Shaft

Latch Handle

Spring [D]

Hook Wires [E]

Washers [F] and Screws [G]

Tail Gate Hook [H]

Bolts [I]

Cargo Bed Installation

•

Apply adhesive agent:

Cargo Bed Rubber Dampers (Bottom)

•

Install:

Cargo Bed Rubber Dampers [A] and [B]

•

Install the small damper [A] on the center of the cargo bed rubber dampers [B] as shown.

[C] 2 mm (0.08 in.)

•

Grease:


•

Install:

Cargo Bed


Snap Pins


Cargo Bed

•

Install:

Rear Fender [A]

Collars [B]

Bolts [C]

Clamp Nut [D]

Screw [E]

Cargo Bed Latch Position Inspection

•

Cargo bed latche [A] must rest securely on the cargo bed hooks [B] without rattling.

If there is rattling or not snug enough, adjust the latch positions.

Cargo Bed Latch Position Adjustment

•

Loosen the mounting bolts [A].

•

Reposition the latch [B] to the suitable place by sliding within the ellipse bolt holes.

•

Retighten the mounting bolts.

FRAME 15-15


15-16 FRAME

Front and Rear Bars

Front Bar Removal

•

Remove:

Front Bar Mounting Bolts (Lower) [A]

Front Bar Mounting Bolts (Upper) [B], Washers and Nuts

Front Bar [C]

Front Bar Installation

•

Tighten:

Torque - Front Bar Mounting Bolts (Lower) [A]: 98 N·m (10 kgf·m, 72 ft·lb)

Front Bar Mounting Bolts (Upper) [B]: 44 N·m (4.5


Washers [C]

Nuts [D]

Rear Bar Removal

•

Remove:

Front Bar Mounting Bolts (Upper) [A], Washers and Nuts

•


•

Remove:

Air Ducts [A]

Rear Bar Mounting Bolts [B]

Rear Bar [C]

Rear Bar Installation

•

Tighten:

Torque - Front Bar Mounting Bolts (Upper) [A]: 44 N·m (4.5


Rear Bar Mounting Bolts (L = 16 mm) [B]: 44 N·m

(4.5 kgf·m, 32 ft·lb)

Rear Bar Mounting Bolts (L = 20 mm) [C]: 44 N·m

(4.5 kgf·m, 32 ft·lb)

Washers [D]

Nuts [E]


Front Fender

Front Fender Installation

•

Install:

Front Fender [A]

Tapping Screw [B] (Hexagon Head)

Tapping Screw [C]

Collars [D]

Well Nut [E]

Headlight Cover [F]

Screws [G]

Washers [H]

FRAME 15-17


15-18 FRAME

Guard and Cover

Front Guard Removal

•

Remove:


Front Cover [B]

•

Remove:

Bolts [A]

Clamp Brackets [B]

Front Guard [C]

Front Guard Installation

•

Install:

Front Guard [A]

Clamp Brackets [B]

Bolts [C]

Dampers [D] (see Exploded View)

Front Cover [E]

Screws [F] and Collars [G]

Floor Center Panel Removal

•

Remove:

Center Cover (see Center Cover Removal)

Tapping Screws [A]

Front Center Panel [B]


FRAME 15-19

Guard and Cover

Floor Center Panel Installation

•

Install:

Front Center Panel [A]

Tapping Screws [B]

Throttle Pedal Bracket [C]

Throttle Pedal Stop Bolt [D] (see Full Throttle Pedal Position Adjustment in the Fuel System chapter)

Locknut [E]

Front Final Gear Case Guard Removal

•

Remove:

Bolts [A]

•

Remove:

Bolts [A]

Front Final Gear Case Guard [B]

Front Final Gear Case Guard Installation

•

Install:

Front Final Gear Case Guard [A]

Bolts [B]

Bottom Guard Removal

•

Remove:

Bolts [A]

Bottom Guard [B]


15-20 FRAME

Guard and Cover

Bottom Guard Installation

•

Install:

Dampers [A]

Bottom Guard [B]

Bolts [C]

Transmission Case Guard Removal

•

Remove:

Bolts [A]

Transmission Case Guard [B]

Transmission Case Guard Installation

•

Install:

Transmission Case Guard [A]

Bolts [B]

Center Cover Removal

•

Remove:

Quick Rivets [A]

Center Cover [B]

Center Cover Installation

•

Install:

Center Cover [A]

Quick Rivets [B]


FRAME 15-21

Guard and Cover

Side Covers Removal

•

Remove:

Quick Rivets [A]

Screws [B] and Collars

Bolts [C] and Collars

Right Side Cover [D]

•

Remove:

Quick Rivets [A]

Screws [B] and Collars

Bolts [C] and Collars

Left Side Cover [D]

Side Covers Installation

•

Install:

Right Side Cover [A]

Quick Rivets [B]

Screws [C] and Collars [D]

Bolts [E] and Collars [D]

•

Install:

Left Side Cover [A]

Quick Rivets [B]

Screws [C] and Collars [D]

Bolts [E] and Collars [D]

Guard Plate Removal

•

Remove:

Air Ducts [A]

Quick Rivets [B]


15-22 FRAME

Guard and Cover

•

Remove:

Quick Rivets [A]

Guard Plate [B]

Guard Plate Installation

•

Install:

Guard Plate [A]

Quick Rivets [B]

Cap [C]

Air Ducts

•

Tighten the clamp screws.


ELECTRICAL SYSTEM 16-1



Exploded View...................................

Wiring Diagram (KAF400-A/C) ..........

16-2

16-6

Wiring Diagram (KAF400-B)..............

16-8

Specifications ....................................

16-10

Special Tools .....................................

16-11

Parts Location....................................

16-12

Precautions........................................

16-14

Electrical Wiring.................................

16-16

Wiring Inspection .........................

16-16

Battery ...............................................

16-17

Battery Removal ..........................

16-17

Battery Installation .......................

16-17

Electrolyte Level Inspection .........

16-17

Electrolyte Specific Gravity

Inspection..................................

16-17

Charging Condition Inspection.....

16-17

Initial Charging .............................

16-18

Ordinary Charging........................

16-19

Battery Test Charging ..................

16-21

Charging System ...............................

16-22

Alternator Rotor and Stator

Removal ....................................

16-22

Alternator Rotor and Stator

Installation .................................

16-24

Charging System Operational

Inspection..................................

16-25

Stator Coil Resistance .................

16-26

Regulator/Rectifier Inspection......

16-26

Ignition System ..................................

16-29

Spark Plug Removal ....................

16-29

Spark Plug Installation .................

16-29

Spark Plug Cleaning/Inspection...

16-29

Spark Plug Gap Inspection ..........

16-29

Ignition Coil Removal ...................

16-29

Ignition Coil Installation ................

16-30

Ignition Coil inspection .................

16-30

Electric Starter System ......................

16-32

Starter Motor Removal.................

16-32

Starter Motor Installation..............

16-32

Starter Solenoid Inspection..........

16-33

Starter Motor Inspection...............

16-33

Starter Motor Disassembly...........

16-34

Starter Motor Assembly ...............

16-36

Starter Motor Brush Inspection ....

16-37

Brush Spring Inspection...............

16-37

Armature Inspection.....................

16-37

Yoke Assembly Inspection ...........

16-39

Pinion Clutch Inspection ..............

16-39

Starter Circuit Relay Inspection ...

16-39

Lighting System .................................

16-42

Headlight Beam Adjustment ........

16-42

Headlight Bulb Replacement .......

16-42

Tail/Brake Light Replacement ......

16-45

Light Switch Bulb Replacement ...

16-46

Indicator Light Bulb Replacement 16-46

Switches ............................................

16-48

Brake Light Switch Inspection......

16-48

Oil Temperature Sensor

Inspection (KAF400-A/C) ..........

16-48

Oil Temperature Warning

Indicator Control Unit Inspection

(KAF400-A/C)............................

16-48

Switch Inspection .........................

16-50

Fuses.................................................

16-51

Fuse Removal..............................

16-51

Fuse Installation...........................

16-51

Fuse Inspection............................

16-51

16


16-2 ELECTRICAL SYSTEM

Exploded View


Exploded View

No.

Fastener

1 Alternator Cover Bolts

2 Alternator Rotor Bolt

3 Ignition Coil Bolts

4 Spark Plug

5 Stator Coil Screws

6 Wire Lead Clamp Bolt

7 Starter Motor Mounting Bolts


N·m

5.9

56

5.9

22

3.4

6.9

17

Torque kgf·m

0.60

5.7

0.60

2.2

0.35

0.70

1.7

ft·lb

52 in·lb

41

52 in·lb

16

30 in·lb

61 in·lb

12

Remarks



Exploded View


Exploded View

No.

Fastener

1 Controller Mounting Bolt (KAF400-A/C)

2 Regulator/rectifier Bolts

3 Joint (KAF400-A/C)

4 Oil Temperature Sensor (KAF400-A/C)

5 Neutral Switch

6. Hour Meter

7. Starter Circuit Relay (Brake)

8. Starter Circuit Relay (Neutral)

9. Accessory Connector (Power Outlet)

10. Light Switch

11. Brake Light Switch

12. Parking Brake Light Switch

G: Apply grease.

CN: Canada Model


N·m

5.4

7.8

7.4

5.5

15

Torque kgf·m

0.55

0.80

0.75

0.56

1.5

ft·lb

48 in·lb

69 in·lb

65 in·lb

49 in·lb

11

Remarks



Wiring Diagram (KAF400-A/C)


Wiring Diagram (KAF400-A/C)




Wiring Diagram (KAF400-B)


Wiring Diagram (KAF400-B)




Specifications

Battery

Capacity

Item

Electrolyte Level

Standard

12 V 14 Ah

Between upper and lower levels

1.270 @20° (68°F) Specific Gravity

Charging System

Regulator/Rectifier Output Voltage

Alternator Stator Coil Resistance

Battery Voltage

∼

15 V

0.3

Ω or less

Ignition system

Ignition Coil:

Air Gap (between leg and magnet) 0.2

∼

0.4 mm (0.0079

∼

0.0157 in.)

Winding Resistance in the text

Spark Plug:

Standard Plug

Spark Plug Gap

Electric Starter System

NGK BPR5ES

0.7

∼

0.8 mm (0.028

∼

0.032 in.)

Starter Motor:

Carbon Brush Length

Connector Groove Depth

Commutator Outside Diameter

10 mm (0.394 in.)

0.5

∼

0.8 mm (0.020

∼

0.031 in.)

28 mm (1.102 in.)

– – – Commutator Runout

Switches

Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel

Oil Temperature Sensor Resistance in the text

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

6 mm (0.236 in.)

0.2 mm (0.008 in.)

27 mm (1.063 in.)

0.4 mm (0.016 in.)

– – –

– – –


Special Tools

Spark Plug Wrench, Hex 21:

57001-110


Hand Tester:

57001-1394



Parts Location

Oil Temperature Warning Indicator Light [A]

Parking Brake Indicator Light [B]

Hour Meter [C]

Ignition Switch [D]

Light Switch [E]

Horn Button [F] (Europe Model)

Brake Light Switch [A]

Starter Circuit Relay (Brake) [A]

Frame Ground Terminal [A]

Parking Brake Light Switch [B]

Regulator/Rectifier [C]

Controller Unit [D] (KAF400-A/C)

Starter Circuit Relay (Neutral) [E]

Battery [F]

Spark Plug [A]


Parts Location

Ignition Coil [A]

Alternator [B]

Oil Temperature Sensor [C] (KAF400-A/C)

Neutral Position Switch [D]

Reverse Position Switch [E] (Europe Model)


Engine Ground Terminal [A]

Accessory Fuse 10 A [A]

Main Fuse 30 A [B]

Battery [C]

Starter Motor [A]

Speed Sensor [B] (Option)

Speed Meter [A] (Option)



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 lead 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 leads 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 leads 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).

○

Color Codes:

BK Black G Green P Pink

BL Blue

BR Brown

GY Gray PU Purple

LB Light Blue R Red

CH Chocolate LG Light Green

W White

DG Dark Green O Orange Y Yellow

○

Electrical Connectors:

Female Connectors [A]


Precautions

Male Connectors [B]




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.

○

Measure the resistance between the ends of the leads.

If the resistance is not 0

Ω, the lead is defective. Replace the lead or the wiring harness if necessary.


Battery

Battery Removal

•

Raise the seat.

•

Disconnect the battery negative (

−) lead [A] first, and then the positive lead [B].

•

Remove:

Battery Holder [C]

•

Take out the battery [D].


Battery Installation

•

Check that the rubber damper [A] is properly in place.

•

Check that the rubber damper [B] under the battery holder

[C] is properly in place.

•

Put the battery on the damper so that the positive terminal faces forward.

•

Install:

Battery Holder

Battery Holder Rods [D]

•

Route the battery bent hose [E] through the hole [F] in the floor board.

•

Connect the positive (+) lead first, and then connect the negative (–) lead.

•

Put a light coat of grease on the terminals to prevent corrosion.

•

Install:

Positive Terminal Cover (Red)

Electrolyte Level Inspection

•

Refer to the Electrical System in the Periodic Maintenance chapter.

Electrolyte Specific Gravity Inspection

•


Charging Condition Inspection

•




Battery

Initial Charging

WARNING

Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. 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.

CAUTION

If the battery is not given a full initial charging, it will discharge in a few weeks. After that it can not be charged by supplemental charging.

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.

Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charger rate can be reduced to the level required.

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:

Battery

Filler Caps

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.


Battery

•

Fill each cell to the upper level line on the battery case with fresh electrolyte (specific gravity: 1.270) at a temperature of 30°C (86°F) or less. Let the battery stand for about 30 minutes before charging.

NOTE

○

If the electrolyte level drops, add electrolyte to the upper level line before charging.

•

Set the charging rate at 1/10 the battery capacity, and

charge it for 10 hours. For example, if the battery is rated at 14 Ah, the charging rate would be 1.4 Ah.

•

Turn the charger off, then disconnect it from the battery.

•

Check:

Electrolyte Level (see Electrolyte Level Inspection)

•

Tighten the filler caps.

Ordinary Charging

WARNING

Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. 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.

CAUTION

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.

Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charger rate can be reduced to the level required.

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:

Battery (see Battery Removal)




Battery

•

Connect a charger to the battery BEFORE plugging it in or turning it on.

•

Set the charging rate and time according to the battery condition previously determined, using the Battery Charging Rate/Time Table.

•

Check the electrolyte level after charging.

•

Turn the charger off or unplug it, then disconnect it from the battery.

•

Check battery condition.

If the battery condition indicates that it is not fully charged, additional charging time is necessary.

Battery Charging Rate/Time Table

Battery Troubleshooting Guide

Plates

Good Battery

(+) Chocolate color

(

−) gray

Sediment none, or small amount

Voltage

Electrolyte Level

Specific Gravity above 12.6 V between upper and lower level lines above 1.240 in all cells; no two cells more than 0.020

different

Suspect Battery white (sulphated); + plates broken or corroded sediment up to plates, causing short below 12.6 V

Action

Replace

Replace

Test charge below lower level line Fill and test charge below 1.100, or difference of more than 0.020 between two cells

Test charge


Battery

Battery Test Charging

If the battery is suspected of being defective, sulfated, or unable to take a charge, consult the table.

•

To test charge a battery, perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below.

Special Tool - Hand Tester : 57001-1394

If the battery voltage suddenly jumps to over 13 V just after the start of charging, the plates are probably sulfated.

A good battery will rise to 12 V immediately and then gradually go up to 12.5 or 13 V in about 30 min. to an hour after the start of charging.

If one cell produces no gas bubbles or has a very low specific gravity, it is probably shorted.

If there does not appear to be enough sediment in a cell to short the plates, but that cell has a very low specific gravity after the battery is fully charged, the trouble may be that there is not enough acid in that one cell. In this case only, sulfuric acid solution may be added to correct the specific gravity.

If a fully charged battery not in loses its charge after 2 to 7 days; or if the specific gravity drops markedly, the battery is defective. The self-discharge rate of a good battery is only about 1% per day.

Sulfation here [A]

Sediment here [B]




Charging System

Alternator Rotor and Stator Removal

•


•

Remove:

Left Rear Wheel (see Wheels/Tires chapter)


2WD/4WD Shift Cable Bracket (KAF400-A/C Models)

Starter Motor (for Stator Coil Removal)

•

Remove:

Alternator Cover Bolts [A]

•

Remove the stoppers [A] of the alternator cover.

•

Remove the alternator cover [A] as shown.


Charging System

•

Remove:

Ignition Coil Lead Connector [A] (disconnect)

Ignition Coil Bolts [B]

Ignition Coil [C]


•

Hold the alternator rotor with a suitable holder [A].

•

Remove:

Alternator Rotor Bolt [B]

Washer [C] and Plate [D]

Cooling Fan [E]

•

Screw the alternator rotor bolt [A].

•

Tap the bolt end sharply and squarely to break the rotor loose, and remove the alternator rotor [B].

CAUTION

Do not attempt to strike the alternator rotor itself.

Striking the rotor can cause the magnets to lose their magnetism.

•

Disconnect:

Alternator Lead Connector [A]

•

Remove:

Starter Motor (see Starter Motor Removal)

Woodruff Key [A]

Stator Coil Screws [B]

Stator Coil [C]



Charging System

Alternator Rotor and Stator Installation

•

Route the stator coil lead according to the Appendix chapter.

•

Install:

Stator Coil

Stator Coil Screws

•

Tighten:

Torque - Stator Coil Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb)

•

Clean [A] the inside of the alternator rotor and the end of the crankshaft, or the taper will not fit snugly.

•

Fit the rotor onto the crankshaft so that the woodruff key

[B] fits in the groove [C] in the hub of the rotor.

•

Insert the projections [A] of the fan in the rotor recesses

[B].

•

Insert the projection [A] of the plate in the groove [B] of the alternator rotor.

•

Install:

Washer [A] and Alternator Rotor Bolt [B]

○

Install the washer as shown.


Charging System

•

Hold the alternator rotor with a suitable holder [A].

•

Tighten:

Torque - Alternator Rotor Bolt [B]: 56 N·m (5.7 kgf·m, 41 ft·lb)


•

Install:

Starter Motor (see Starter Motor Installation)

Ignition Coil (see Ignition Coil Installation)

•

Connect:

Ignition Coil Lead Connector

•

Install:

Alternator Cover

○

Fit the stoppers [A] the alternator cover.

•

Tighten:

Torque - Alternator Cover Bolt: 5.9 N·m (0.60 kgf·m, 52 in·lb)

•


Charging System Operational Inspection

•

Check battery condition (see Charging Condition Inspection in the Periodic Maintenance chapter).

NOTE

○

Always check battery condition before condemning other parts of the charging system. The battery must be fully charged in order to conduct accurate charging system tests.

•

Warm up the engine to bring the components up to their normal operating temperatures.

•

Measure regulator/rectifier output voltage at various engine speeds with the headlights turned on and then turned off.

○

Connect a voltmeter across the battery terminals.

•

The readings should show nearly battery voltage when the engine speed is low, and as the engine speed rises, the readings should also rise. But they must stay within the specified range.

If the output voltage is much higher than the specification, the regulator/rectifier is defective, or the regulator/rectifier leads are loose or open.

If the output voltage does not rise as the engine speed increase then the regulator/rectifier is defective or the alternator output is insufficient for the loads.

Regulator/Rectifier Output Voltage

Standard: Battery Voltage

∼

15 V



Charging System

Stator Coil Resistance

•

Disconnect the alternator leads connector.

•

Measure the stator coil resistance.

○

Connect an ohmmeter between the alternator leads.

Stator Coil Resistance

Standard: 0.3

Ω or less

If the meter does not read as specified, replace the alternator stator.

If the coil has normal resistance, but the voltage inspect showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.

Regulator/Rectifier Inspection

•

Remove the regulator/rectifier [A].

Rectifier Circuit Test

•

Check the resistance in both directions between the terminals following the table.

Tester Connection

W-G/W1, W-G/W2

BK/Y-G/W1, BK/Y-G/W2

The resistance should be low in one direction and more than ten times as much in the other direction. If any two terminals are low or high in both directions, the rectifier is defective and 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 the first 1/2 of the scale.

Regulator Circuit Test

•

Prepare testing tools:

Test Light Bulb rated 12 V and 3

∼

6 W (with socket and leads)

Batteries

Test Leads

Three 12 V batteries

Four auxiliary leads

CAUTION

The test light limits the current flow through the regulator/rectifier. Do not use an ammeter or multimeter in its place.


Charging System

Regulator Circuit Test-1st Step:

•

Connect the test light and the 12 V battery to the regulator/rectifier as shown.

•

Check G/W1 and G/W2 terminals respectively.

CAUTION

The test light limits the current flow through the regulator/rectifier. Do not use an ammeter or multimeter in its place.

If the test light turns on, the regulator/rectifier is defective.

Replace it.

If the test light does not turn on, continue the test.

Regulator Circuit Test-2nd Step:

•

Connect the test light and the 12 V battery in the manner as specified in the "Regulator Circuit Test-1st Step."

•

Apply 12 V to BR terminal.

•


If the test light turns on, the regulator/rectifier is defective.

Replace it.

If the test light does not turn on, continue the test.


Regulator Circuit Test-3rd Step:

•

Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st

Step."

•

Momentarily apply 24 V to BR terminal by adding a 12 V battery.

•


CAUTION

Do not apply more than 24 V to the regulator/rectifier and do not leave the 24 V applied for more than a few seconds, or the unit will be damaged.

If the test light did not light when the 24 V was applied momentarily to the BR terminal, the regulator/rectifier is defective. Replace it.

If the regulator/rectifier passes all of the tests described, it may still be defective. If the charging system still does not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.



Charging System

Charging System Circuit

1. Ignition Switch

2. Alternator

3. Regulator/Rectifier

4. Battery

5. 30 A Fuse

6. Load


Ignition System

WARNING

The ignition system produces extremely high voltage. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock.

CAUTION

Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent

IC igniter damage.

Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the diodes and IC igniter.

Spark Plug Removal

•

Remove:


Spark Plug Cap [A]

•

Remove the spark plug using the plug wrench [B].

Special Tool - Spark Plug Wrench, Hex 21: 57001-110


Spark Plug Installation

•

Tighten:

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

•

Fit the spark plug cap securely.

•

Pull up the spark plug cap lightly to make sure of the installation of the spark plug cap.

Spark Plug Cleaning/Inspection

•

Refer to the Spark Plug Cleaning/Inspection in the Periodic Maintenance chapter.

Spark Plug Gap Inspection

•

Refer to the Spark Plug Gap Inspection in the Periodic


Ignition Coil Removal

•

Remove:

Alternator Cover (see Alternator Rotor and Stator Removal).

Ignition Coil Lead Connector [A] (disconnect)

Ignition Coil Bolts [B]

Ignition Coil [C]



Ignition System

Ignition Coil Installation

•

Install:

Ignition Coil [A]

Ignition Coil Bolts

•

While tightening the bolts, adjust the air gap [B] between the leg of ignition coil and the magnet to the specified gap value as shown.

Ignition Coil Air Gap

Standard: 0.2

∼

0.4 mm (0.0079

∼

0.0157 in.)

•

Tighten the ignition coil bolts following the tightening sequence [1

∼

2].

Torque - Ignition Coil Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)

NOTE

○

Above procedure must be used to insure proper coil air gap is not too large.

Ignition Coil inspection

•

Remove the ignition coil (see Ignition Coil Removal).

•

Measure the winding resistance as follows.

○

Set the hand tester to the R × 1 k

Ω range.

Special Tool - Hand Tester: 57001-1394

○

Make the measure shown in the table.

Ignition Coil Winding Resistance

+

A

–

A

B

C

–

∞

2

∼

18 k

Ω

B

2

∼

18 k

Ω

–

2

∼

18 k

Ω

C

2

∼

18 k

Ω

∞

–

CAUTION

Use only Tester 57001-1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester may show different readings.

If a meter with a large-capacity battery is used, the ignition coil will be damaged.

If the tester does not read as specified, replace the coil.


Ignition System

Ignition System Circuit


1. Ignition Switch

2. Ignition Coil

3. Spark Plug

4. Alternator Rotor




Starter Motor Removal

•

Remove:


Connecting Plate Bolts [A]

Connecting Plate [B]

•

Remove:

Governor Cover [A]

Transmission Shift Cable End Lever [B]

Bracket [C]

•

Remove:

Starter Motor Lead [A] and Connector [B]

Hose [C]

•

Remove:

Starter Motor Mounting Bolts [A]

Starter Motor [B]

Starter Motor Installation

•

Clean the mating surface of the starter motor [A] and the crankcase [B] where the starter motor is grounded.



•

Install the starter motor [A] to the engine as shown.

•

Tighten:

Torque - Starter Motor Mounting Bolts: 17 N·m (1.7 kgf·m,

12 ft·lb)


Starter Solenoid Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove:


•

Disconnect the starter motor lead [A].

•

Connect the hand tester [A] and a 12 V battery to the starter motor solenoid [B] as shown.

○

Set the hand tester to ×1

Ω range, connect the tester leads to the stud terminals [C].

○

Connect the battery:

(+) Terminal to Solenoid Terminal [D]

(–) Terminal to Solenoid Body [E]

If the solenoid does not work as specified as follows, the solenoid is defective. Replace the solenoid.

Testing Solenoid

Hand Tester Range: × 1

Ω

Criteria: When battery is connected

→ click sound and 0

Ω

When battery is disconnected

→ ∞ Ω

Starter Motor Inspection

•

Inspect the starter solenoid (see Starter Solenoid Inspection).

•

Hold the starter motor in a vise.

CAUTION

Be careful not to deform the starter motor body when holding it in a vise.

•

Install:

Starter Motor Lead [A]

Nut [B]




•

Connect a 12 V battery to the starter solenoid [A] as shown.

○

Connect the battery negative (–) cable [B] to the starter motor body.

○

Connect the battery positive (+) cable [C] to the stud terminal [D].

•

Connect the switching lead [E] to the battery positive (+) terminal.

Testing Starter Motor

Criteria:

When switching lead is connected

→

Pinion gear must move outward.

When switching lead is disconnected

→

Pinion gear must return quickly.

If the starter motor does not work as specified, the starter motor is defective. Replace the starter motor.

Starter Motor Disassembly

•

Remove:


Starter Motor Lead Nut [A]

Starter Motor Lead [B]

•

Remove:

Nuts [A]

Starter Solenoid [B]

•

Remove:

Starter Motor Through Bolts [A]

Pinion Gear Cover [B]

•

Slip the actuating arm [C] from the pinion gear.



•

Pull the armature [A] from the yoke [B].


•

Separate the front stopper [A] and rear stopper [B] each other and remove the front stopper to left side [C] as shown the figure.

•

Push the rear stopper to right side [D] and remove the snap ring [E] as shown the figure.

•

Pull the rear stopper and pinion gear [F] from the armature shaft.

•

Gently pull the end cover [A] from the yoke and remove the insulator [B].

•

Using a needle nose pliers, remove the brush springs [A] from the brush holder [B].

•

Separate the brushes [C] from the holder and remove the holder from the yoke [D].




Starter Motor Assembly

•

Apply a small amount of grease to the armature shaft [A] as shown.

•

Do not reuse the snap ring [B]. Replace it with a new one.

•

Inspect the rubber insert [A] and/or boot [B] for visible damage.

If they are damaged, replace them.

•

Fit the notch [A] in the (-) lead grommet onto the projection

[B] on the end cover [C].

•

Grease the pinion gear fork fingers.

•

Set the pinion gear fork so that the fingers fit into the groove in the gear.

•

Fit the notch [A] in the yoke onto the projection [B] on the pinion gear fork.



•

Engage the hook on the starter solenoid with the hook [A] on the pinion gear fork [B].


Starter Motor Brush Inspection

•

Measure the overall length of each brush [A].

If the brushes are shorter than the service limit, replace them.

Carbon Brush Length

Standard: 10 mm (0.394 in.)


Brush Spring Inspection

•

Inspection the brush springs for pitting, cracks, rusting and burrs. Replace the spring if necessary.

•

Inspect the springs for weakened conditions and distortion. Replace the springs if necessary.

If the brush springs are able to press the brushes firmly into place, they may be considered serviceable. If they cannot, replace them.

Armature Inspection

•

Inspect the surface of the commutator [A].

If it is scratched or dirty, polish it with a piece of very fine emery cloth [B], and clean out the grooves.

•

Measure the depth of the grooves between the commutator segments.

If the grooves are shallower than the specified limit, undercut the insulating material to the standard depth 0.5 to

0.8 mm (0.012 to 0.031 in) using a thin file.

If the grooves are only dirty, clean them carefully.

Commutator Groove Depth

Standard: 0.5

∼

0.8 mm (0.020

∼

0.031 in.)


Bad [A]

Segment [B]

Good [C]

0.2 mm (0.008 in.) limit [D]

Mica [E]




•

Measure the commutator [B] outside diameter [A] at several points.

If the diameter is less than the service limit, replace the armature with a new one.

Commutator Outside Diameter

Standard: 28 mm (1.102 in.)


•

Support the armature in an alignment jig at each end of the shaft as shown. Position a dial indicator perpendicular to the commutator.

•

Rotate the armature slowly and read the commutator runout.

If runout is more than the service limit, replace the armature with a new one.

Commutator Runout


•

Measure the armature winding resistance.

○

Set the multimeter selector switch to the R × 1

Ω position and check the resistance between each segment and all the others.

If the resistance it too high or even infinite, the armature winding has an open circuit. Replace the starter motor.

Armature Winding Resistance

Close to 0

Ω

•

Set the multimeter selector switch to the R × 1 k

Ω position and measure the resistance between the commutator and the armature shaft.

If the resistance is less than infinite, the armature is shorted.

Commutator to Shaft Resistance

(

∞)

•

Test the armature winding for shorts.

○

Place the armature on a growler [A].

○

Hold a thin metal strip (e.g., hack saw blade) on top of the armature.

○

Turn on the growler and rotate the armature one complete turn.

If the metal strip vibrates, the windings are internally shorted to each other and the starter motor must be replaced.



Yoke Assembly Inspection

•

Set the multimeter selector switch to the R × 1 k

Ω position and measure the resistance between the positive brushes and stator motor yoke.

If the resistance is less than infinite, the positive brush is shorted to ground. Replace the yoke assembly.

Positive Brush to Ground Resistance

(

∞)


•

Set the multimeter selector switch to the R × 1

Ω position and measure the resistance between the negative brushes and starter motor yoke.

If the meter dose not read close to 0

Ω, the yoke assembly is faulty. Replace it.

Negative Brush to Ground Resistance

Close to 0

Ω

Pinion Clutch Inspection

•

Remove the pinion clutch.

•

Turn the pinion gear by hand. The pinion gear should turn counterclockwise freely, but should not turn counterclockwise.

If the pinion clutch dose not operate as it should, or if it makes noise, replace the pinion clutch.

Starter Circuit Relay Inspection

•

Remove:

Starter Circuit Relay (Neutral) [A]

Starter Circuit Relay (Brake) [B]




•

Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown.

If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay

Hand Tester Range: × 1

Ω

Criteria: When battery is connected

⇒ 0Ω

When battery is disconnected

⇒ ∞Ω

Relay Coil Terminals [1] and [2]

Relay Switch Terminals [3] and [4]



Electric Starter Circuit


1. Ignition Switch

2. Starter Motor


4. Neutral Switch


6. Brake Switch

7. Battery

8. 30 A Fuse



Lighting System

Headlight Beam Adjustment

•

Turn the adjusting screw [A] on each headlight rim in or out to adjust the headlight vertically.

Headlight Bulb Replacement

•

Remove:

Screws [A]

Collar [B]

Headlight Assembly [C]

•

Remove:

Adjusting Screw [A]

Bolts [B] and Washers

Headlight Cover [C]

•

Disconnect:

Connectors [A]

•

Remove:

Dust Cover [A]

•

Push and turn the bulb holder [B] counterclockwise and remove it.


Lighting System

•

Remove:

Headlight Bulb [A]

•

Insert the new bulb [A] by aligning the tang [B] with the notch [C] in the head light unit.

•

Insert the bulb holder [A] by aligning the tangs [B] with the notches [C] in the head light unit.

•

Push and turn the bulb holder counterclockwise and remove it.

•

Fit the dust cover [A] with the TOP mark [B] upward (to position light) firmly.

•

Push and turn the bulb socket [A] counterclockwise and remove it.




Lighting System

•

Remove the wedge-base type bulb [A]; pull the bulb straight out of the socket [B].

CAUTION

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 bulb socket [A] by aligning the longer projections [B] with the longer recesses [C] in the head light body.

•

Install:

Spring [A] and Adjusting Screw

•

Install the nut [B] so that the flat side faces upward.

•

Insert the headlight lead [A] in the grommet [B], and install it in the headlight body.


Lighting System

•


Nuts [A]

Dampers [B]

Collars [C]

Washers [D]

Bolts [E]

Collar [F]

Screws [G]


Tail/Brake Light Replacement

•

Remove:

Screws [A]

Tail/Brake Light Lens [B]

•

Push the bulb [A] in, turn it counterclockwise, and pull it out of the socket.

CAUTION

Do not use bulbs rated for greater wattage than the specified value.

•

Insert the new bulb by aligning the pins [A] with the grooves in the walls of the socket.

•

Push the bulb in, turn it clockwise, and release it. It should be lock in position.

•

Install:

Tail/Brake Light Lens

Screws

○

Be careful not to overtighten the lens mounting screws.



Lighting System

Light Switch Bulb Replacement

•

Remove:


•

Turn the socket [A] counterclockwise, and pull it with the bulb.

•

Pull the bulb [A] out of the socket.

CAUTION



•

Insert the new bulb in the socket.

•

Align the projections [B] of the socket with the recesses

[C] in the switch body, and turn the socket clockwise.

Indicator Light Bulb Replacement

•

Remove:

Light Assembly [A]

Lens [B]

•

Roll the rubber [A] up and pull the bulb [B] out of the socket.

CAUTION



•

Install:

Bulb

Lens [A]

Light Assembly [B]


Lighting System

Lighting System Circuit


1. Light Switch

2. Ignition Switch

3. Headlights

4. Position Lights

5. Brake/Tail Lights

6. Brake Switch

7. 30 A Fuse

8. Battery


10. Parking Brake Light



Switches

Brake Light Switch Inspection

•

Refer to Brake Light Switch Inspection in the Periodic


Oil Temperature Sensor Inspection (KAF400-A/C)

•

Remove:

Oil Temperature Sensor [A] (see Engine Lubrication System chapter)

•

Suspend the sensor in a container of engine oil so that the heat-sensitive portion and threaded portion are submerged.

•

Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.

NOTE

○

The sensor and thermometer must not touch the container side or bottom.

•

Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature.

•

Using the hand tester, measure the internal resistance of the sensor across the terminals at the temperatures shown in the table.

If the hand tester does not show the specified values, replace the sensor.

Oil Temperature Sensor Resistance

Temperature

50°C (122°F)

100°C (212°F)

150°C (302°F)

200°C (392°F)

Resistance ( k

Ω)

64.07

∼

92.93

11.29

∼

15.03

2.68

∼

3.84

0.87

∼

1.28

Oil Temperature Warning Indicator Control Unit

Inspection (KAF400-A/C)

•

Remove:

Left Side Cover (see Frame chapter)

Oil Temperature Warning Indicator Control Unit [A]

•

Set the hand tester to ×1 k

Ω range and make sure the measurements shown in the table.

Special Tool - Hand Tester: 57001-1394

If the tester readings are not as specified, replace the control unit.

CAUTION

Use only Tester 57001-1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester may show different readings.

control unit will be damaged.


Switches

Internal Resistance

(–)

Terminal

1

2

3

4

5

6

1

–

∞

∞

∞

∞

∞

(–): Tester (–) Lead Connection

Tester (+) Lead Connection

2 3 4 5

32.5

∼

97.5 28.0

∼

84.0 17.0

∼

51.0 32.5

∼

97.5

32.5

–

27.5

∼

82.5

∼

25.0

∼

75.0

97.5 28.0

–

∼

84.0

17.0

∼

51.0 25.0

∼

75.0

∞

∞

–

∞

17.0

27.5

∼

∼

–

51.0

82.5

32.5

∼

97.5

∞ ∞ ∞ ∞

Unit: k

Ω

6

∞

∞

∞

∞

∞

–

Oil Temperature Warning Control System Circuit

1. Ignition Switch

2. Oil Temperature Warning Indicator Control Unit

3. Oil Temperature Sensor

4. Oil Temperature Warning Indicator Light

5. 30 A Fuse

6. Battery



Switches

Switch Inspection

•

Using a hand tester, check to see that only the connections shown in the table have continuity (about zero ohms).

○

For the ignition switch, light switch, brake light switch, and parking brake light switch, refer to tables in the Wiring

Diagram.

If the switch has an open or short, repair it or replace it with a new one.

Neutral Switch Connections

Reverse Light Switch Connections (Europe Model)

Horn Switch Connections (Europe Model)


Fuses

Fuse Removal

•

Remove:

30 A Fuse Case [A]

10 A Fuse Case [B]

•

Open the fuse case and remove the fuse.

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.

10 A Fuse Case [A]

Brown Lead [B]

30 A Fuse Case [C]

White Lead [D]

Fuse Inspection

•

Remove the fuse.

•

Inspect the fuse element [A].

If it is blown out, replace the fuse. Before replacing a blown fuse [B], 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.

CAUTION

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.




APPENDIX 17-1

Appendix


Troubleshooting Guide ...........................................................................................................

Cable, Wire, and Hose Routing ..............................................................................................

17-2

17-6

17


17-2 APPENDIX

Troubleshooting Guide

NOTE

○

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.

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,

Engine Doesn’t Start, Starting Difficulty:

worn, or carbon accumulation on the

Starter motor not rotating:

seating surface)

Neutral switch trouble

Poor Running at Low Speed:

Starter motor trouble

Spark weak:

Battery voltage low

Spark plug dirty, broken, or maladjusted

Relays not contacting or operating

Spark plug cap or high tension wiring trou-

Wiring open or shorted ble

Ignition switch trouble

Spark plug cap shorted or not in good con-

Fuse blown tact

Starter motor rotating but engine doesn’t

Spark plug incorrect

turn over:

Ignition coil trouble

Starter motor trouble

Fuel/air mixture incorrect:

Pinion or ring gear worn

Air cleaner clogged, poorly sealed, or miss-

Engine won’t turn over:

ing

Valve seizure

Choke valve stuck closed

Rocker arm seizure

Fuel level too high or too low

Cylinder, piston seizure

Fuel tank air vent obstructed

Crankshaft seizure

Fuel pump trouble

Connecting rod small end seizure

Governor link mechanism malfunctioning

Connecting rod big end seizure

Compression low:

Camshaft seizure

Spark plug loose

No fuel flow:

Cylinder head not sufficiently tightened

Fuel tank air vent obstructed down

Fuel pump trouble

No valve clearance

Fuel filter clogged

Cylinder, piston worn

Fuel line clogged

Piston ring bad (worn, weak, broken, or

Float valve clogged sticking)

Engine flooded:


Fuel level too high


Float valve worn or stuck open


Starting technique faulty


(When flooded, crank the engine with the

Valve not seating properly (valve bent, throttle fully opened to allow more air to worn, or carbon accumulation on the reach the engine.) seating surface)

No spark; spark weak:

Other:


Engine oil viscosity too high

Spark plug cap or high tension wiring trou-

Front final gear case oil viscosity to high ble

(KAF400-A/C)

Spark plug cap not in good contact

Drive train trouble


Brake dragging

Ignition coil trouble

Poor Running or No Power at High Speed:

Ignition switch shorted

Firing incorrect:

Wiring shorted or open


Fuse blown

Spark plug cap shorted or not in good con-

Compression Low:

tact

Spark plug loose


Cylinder head not sufficiently tightened

Ignition coil trouble down

No valve clearance



APPENDIX 17-3


Fuel level too high or too low

Air cleaner clogged, poorly sealed, or missing

Water or foreign matter in fuel

Fuel tank air vent obstructed

Fuel line clogged

Fuel pump trouble

Governor link mechanism malfunctioning

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened down

No valve clearance


Piston ring bad (worn, weak, broken, or sticking)





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


Miscellaneous:

Throttle valve won’t fully open

Brake dragging

Overheating

Engine oil level too high


Front final gear case oil viscosity too high

(KAF400-A/C)

Drive train trouble

Overheating:

Firing incorrect:




Main jet clogged or wrong size

Fuel level too low

Air cleaner clogged, poorly sealed, or missing

Compression high:


Engine load faulty:

Engine oil level 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

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

(KAF400-A/C):

Insufficient oil

Bevel gears maladjusted

LSD clutch maladjusted

Cooling system component incorrect:

Fan blade damaged

Screen air passages clogged

Converter Operation Faulty:

Belt slipping:

Belt dirty or worn



Converter engagement speed too low:


Converter engagement speed too high:

Belt 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 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

17-4 APPENDIX


Transmission shaft, and/or gear splines worn


Overshifts:

Shift arm positioning bolt spring weak or broken


Abnormal Engine Noise:

Knocking:


Fuel poor quality or incorrect


Overheating

Piston slap:

Cylinder/piston clearance excessive


Connecting rod bent

Piston pin, piston pin holes worn

Valve noise:

Valve clearance incorrect


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 mounts loose

Crankshaft bearing worn

Loose alternator rotor

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:

Bearing worn

Transmission gears worn or chipped

Metal chips jammed in gear teeth

Transmission oil insufficient

Final drive noise:

Bearing worn

Metal chips jammed in gear teeth

Insufficient lubricant

Bevel gears maladjusted (KAF400-A/C)

Worn LSD clutch friction plate (KAF400

-A/C)

Worn LSD clutch spring (KAF400-A/C)

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, nuts, bolts, 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 to high

Black smoke:

Air cleaner clogged

Main jet too large or fallen off

Choke valve stuck closed

Fuel level too high

Brown smoke:

Main jet too small

Fuel level too low

Air cleaner poorly sealed or missing

Handling and/or Stability Unsatisfactory:

Steering wheel hard to turn:

Steering shaft bearing damaged

Steering shaft lubrication inadequate

Steering shaft bent

Steering gear assembly damaged

Tire air pressure too low

LSD clutch maladjusted (KAF400-A/C)

Noise when turning (KAF400-A/C):

Damaged side gear or pinion (front final gear case)

Worn clutch friction plates (Front final gear case)

Worn clutch spring (Front final gear case)

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

Shock absorption unsatisfactory:

(Too hard)

Tire air pressure too high

Shock absorber damaged

(Too soft)

Shock absorber oil leaking

Shock absorber spring weak

Tire air pressure too low

Brake Doesn’t Hold

Air in the brake line

Brake fluid leak

Brake fluid deteriorated

Primary or secondary cup trouble

Master or wheel cylinder scratched inside

Brake not properly adjusted

Lining overworn or worn unevenly

Drum worn unevenly or scored

Oil, grease on lining and drum

Dirt, water between lining and drum

Overheated brakes

APPENDIX 17-5

Battery Discharged:

Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte level too low)

Battery leads making poor contact

Load excessive (e.g., bulb of excessive wattage)

Ignition switch trouble

Regulator/Rectifier trouble

Alternator trouble

Wiring faulty

Battery Overcharged:

Regulator/Rectifier trouble

Battery trouble


17-6 APPENDIX

Cable, Wire, and Hose Routing

1. Band

2. Brake Panel Breather Hose

3. Accessory Connector (Power Outlet) Lead

4. Ignition Switch Lead

5. Hour Meter

6. Parking Brake Indicator Light Lead

7. Oil Temperature Warning Indicator Light Lead (KAF400-A/C)

8. Horn Switch Lead (Europe Model)

9. Light Switch Lead

10. Green Tape (Left Side)

11. Head Light Lead

12. Front Final Gear Case Breather Hose (KAF400-A/C)

13. Hour Meter Lead

15. Oil Temperature Warning Indicator Light Lead (KAF400-A/C)


APPENDIX 17-7

1. Connector Cover

2. Band

3. Taping (All Around)

4. “0” Gap

5. Snap Pin

6. Washer

7. Pin

8. 8

∼

14 mm (0.32

∼

0.55 in.)


17-8 APPENDIX


1. Headlight Lead

2. Quick Rivet

3. Clamp

4. Harness

5. Red Tape (Right Side)

6. Headlight Lead

7. Clamp

8. Main Harness

9. Differential Lock Shift Cable

10. Choke Cable

11. Transmission Shift Cable


13. Throttle Cable


APPENDIX 17-9

1. Horn (Europe Model)

2. Washer

3. Collar

4. Screw

5. Horn Lead

6. Screw

7. Steering Gear Assembly

8. Main Harness


10. Choke Cable



13. Throttle Cable

17-10 APPENDIX


1. Main Harness


3. Choke Cable



6. Throttle Cable

7. Brake Pipe

8. 14 mm (0.55 in.)

9. 20 mm (0.79 in.)

10. Rear Left Brake Cable

11. Rear Right Brake Cable

12. Bands



APPENDIX 17-11

1. Engine Mounting Bolt

2. Engine Ground Lead

3. 0

∼

2 mm (0

∼

0.08 in.)

4. Choke Cable

5. Cooling Fan Cover

6. Bands


8. Throttle Cable

9. Starter Motor

10. (+) Lead

11. Push the lead and change the route.

12. 10 mm (0.39 in.)


17-12 APPENDIX


1. Accessory Fuse 10 A

2. Fuse 30 A

3. Battery

4. Engine Ground Lead

5. Starter Motor Lead

6. Frame Ground Lead




10. Regulator/rectifier

11. Oil Temperature Warning Indicator Control Unit (KAF400-A/C)



APPENDIX 17-13

1. Tail/brake Light Leads

2. Reverse Light Leads (Europe Model)

3. Rear Brake Panel Breather Hose

4. Main Harness

5. Clamp

6. Brake Pipe


17-14 APPENDIX


1. Alternator Lead

2. Ignition Coil Lead

3. Oil Temperature Warning Indicator Control Unit Lead (KAF400-A/C)

4. Neutral Switch

5. Reverse Switch Lead Connector (for option)

6. Speed Sensor Lead (for option)

7. Clamp

8. Reverse Switch (Europe Model)



APPENDIX 17-15

1. Clamp (Clamp the Breather Tube and Harness.)

2. Large Size Side

3. Small Size Side

4. Harness

5. Run the breather hose between the starter motor and control panel Assembly.

6. Breather Tank

7. Clamps

8. Starter Motor

9. Clamps

10. Braket

11. Control Panel Assembly.


17-16 APPENDIX


1. Plug

2. Insert the plug until the plug’s flange contact on this side.

3. Clamps

4. Good

5. Bad

6. Clamps

7. Belt Converter Air Cleaner



APPENDIX 17-17

1. Fuel Filter

2. Fuel Tank

3. Band

4. Frame Pipe

5. Fuel Hose

6. Fuel Pump

7. Vacuum Hose

8. Fuel Hose

9. Breather

10. Starter Motor

11. Clamp

12. Carburetor

13. The distance between the fuel hose end and protector end is about 80 mm (3.15 in.)


17-18 APPENDIX


1. Air Cleaner

2. Clamp

3. Air Duct

4. Carburetor

5. Clamp

6. Clamp

7. Drain Tube

8. Clamp



APPENDIX 17-19

1. Band

2. Front Final Gear Case Breather Hose

3. Grommet

4. Clamp

5. Front Final Gear Case


17-20 APPENDIX


1. Breather Hose

2. Brake Hose

3. Clamp

4. Clamp

5. Clamp Bracket

6. Front Guard

7. Grommet

8. Bands

9. Bolt

10. Bracket

11. Knuckle

12. Retainer

13. Brake Pipe

15. Front Brake Panel

Year

2005

2005

2005

MODEL APPLICATION

Model

KAF400-A1

KAF400-B1

KAF400-C1

Beginning Frame No.

JK1AFEA1

□

5B500001

JK1AFEB1

□

5B500001

JK1AF400BBB600001

JK1AFEC1

□

5B500001

□

:This digit in the frame number changes from one machine to another.

Printed in Japan

Kawasaki MULE 610 4X4 - DATASHEET 2011 Service manual

Utility Vehicle

Service Manual

Quick Reference Guide

Utility Vehicle

Service Manual

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

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.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

(United States Model only)

Foreword

This note symbol indicates points of particular interest for more efficient and convenient operation.

How to Use This Manual

GENERAL INFORMATION 1-1

General Information

1-2 GENERAL INFORMATION

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

GENERAL INFORMATION 1-3

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

1-4 GENERAL INFORMATION

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Locking Agent

Press

GENERAL INFORMATION 1-5

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

1-6 GENERAL INFORMATION

Lubrication

Direction of Engine Rotation

Electrical Wires

GENERAL INFORMATION 1-7

1-8 GENERAL INFORMATION

GENERAL INFORMATION 1-9

1-10 GENERAL INFORMATION

GENERAL INFORMATION 1-11

1-12 GENERAL INFORMATION

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

2-4 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-7

2-8 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-9

2-10 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-11

2-12 PERIODIC MAINTENANCE

Throttle Pedal Free Play Inspection

Throttle Pedal Free Play Adjustment

Idle Speed Inspection

Idle Speed Adjustment

PERIODIC MAINTENANCE 2-13

Air Cleaner Element Cleaning

2-14 PERIODIC MAINTENANCE

Fuel Hoses And Connections Inspection

Fuel Hoses Replacement

PERIODIC MAINTENANCE 2-15

Fuel Filter Replacement

2-16 PERIODIC MAINTENANCE

Fuel System Cleanliness Inspection

Valve Clearance Inspection