tables. Kawasaki MULE 610 4X4 - DATASHEET 2011, MULE 600 SERIES, MULE 610 4×4
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Kawasaki MULE 610 4X4 2011 The Kawasaki MULE 610 4X4 2011 is a versatile and powerful side-by-side utility vehicle designed for a wide range of tasks, from hauling cargo and equipment to exploring off-road trails. With its robust construction, comfortable seating, and advanced features, the Kawasaki MULE 610 4X4 2011 is an ideal choice for farmers, ranchers, outdoor enthusiasts, and anyone who needs a reliable and capable utility vehicle.
Key Features:
- 617cc 4-stroke, air-cooled, OHV engine with electric fuel injection
- CVT transmission with high and low ranges
- 4WD with locking front differential
- Independent front and rear suspension
- Hydraulic disc brakes
- Comfortable seating for two
- Large cargo bed with a capacity of 1,000 lbs.
- Towing capacity of 2,000 lbs.
- Plenty of storage compartments and accessories available
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MULE 610 4×4
MULE 600
Utility Vehicle
Service Manual
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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.
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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.
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© 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.
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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.
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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.
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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
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GENERAL INFORMATION 1-1
General Information
Table of Contents
1
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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.
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Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
GENERAL INFORMATION 1-3
Storage of Removed Parts
After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips 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.
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1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
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.
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Before Servicing
Press
For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
GENERAL INFORMATION 1-5
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
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1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from 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.
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Model Identification
KAF400-A1 Left Side View
GENERAL INFORMATION 1-7
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.
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1-8 GENERAL INFORMATION
Model Identification
KAF400-B1 Left Side View
KAF400-B1 Right Side View
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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
GENERAL INFORMATION 1-9
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)
1-10 GENERAL INFORMATION
General Specifications
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.)
GENERAL INFORMATION 1-11
General Specifications
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
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1-12 GENERAL INFORMATION
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:
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PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Periodic Maintenance Chart ..............
Torque and Locking Agent.................
Specifications ....................................
Special Tools .....................................
Periodic Maintenance Procedures.....
Fuel System....................................
Inspection..................................
Adjustment ................................
Idle Speed Inspection ..................
Idle Speed Adjustment.................
Air Cleaner Element Cleaning......
Inspection..................................
Fuel Hoses Replacement.............
Fuel Filter Replacement...............
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 .
Inspection..................................
Cleaning/Inspection...................
Converter Dust or Water Drain ....
Engine Lubrication System .............
Engine Oil Change.......................
Oil Filter Replacement .................
Transmission ..................................
Transmission Oil Change.............
Table of Contents
Wheels/Tires ...................................
Inspection..................................
Tire Wear Inspection ....................
Final Drive (KAF400-A/C models) ..
Change......................................
Brakes.............................................
Brake Fluid Level Inspection........
Brake Fluid Change .....................
Brake Pedal Play Inspection ........
Dust Seal Replacement ............
Brake Hose and Pipe Inspection..
Replacement .............................
Brake Wear Inspection.................
Replacement .............................
Parking Brake Lever Inspection ...
Steering ..........................................
Steering Inspection ......................
Inspection..................................
Frame .............................................
Seat Belt Inspection .....................
Electrical System ............................
Spark Plug Cleaning/Inspection...
Spark Plug Gap Inspection ..........
Electrolyte Level Inspection .........
Inspection..................................
Brake Light Switch Inspection......
General Lubrication ........................
Bolts, Nuts, and Fasteners .............
Tightness Inspection ....................
2
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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
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PERIODIC MAINTENANCE 2-3
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
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2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket.
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
Converter System
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
Property of www.SmallEngineDiscount.com - Not for Resale
Torque and Locking Agent
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
Engine Lubrication System
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 Removal/Installation
Engine Mounting Bolts and Nuts
Connecting Plate Bolts (M8)
Connecting Plate Bolts (M10)
Engine Bottom End
Connecting Rod Bolts
Breather Valve Screw
Oil Filter Joint
Oil Line Plugs
Crankcase Cover Bolts
Engine Oil Drain Plugs
Transmission
Transmission Cable Holder Bolts
Connecting Plate Bolts (M8)
Connecting Plate Bolts (M10)
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
PERIODIC MAINTENANCE 2-5
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
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
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
Wheel Cylinder Mounting Bolts
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
Torque and Locking Agent
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
Electrical System
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
PERIODIC MAINTENANCE 2-7
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
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2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
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
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PERIODIC MAINTENANCE 2-9
Specifications
Item Standard
Fuel System
Throttle Pedal Free Play
Idle Speed
Engine Top End
Valve Clearance (when cold) 0.10
∼
0.15 mm (0.0039
∼
0.0059 in.)
Converter System
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 Lubrication System
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
DUNLOP KT869, Tubeless
(B) 22 × 11.00 × 10
DUNLOP KT869, Tubeless
– – –
– – –
– – –
– – –
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 – – –
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2-10 PERIODIC MAINTENANCE
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
Electrical System
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.)
– – –
– – –
– – –
– – –
– – –
– – –
– – –
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Special Tools
Inside Circlip Pliers:
57001-143
PERIODIC MAINTENANCE 2-11
Oil Filter Wrench:
57001-1249
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2-12 PERIODIC MAINTENANCE
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.
•
Tilt up the cargo bed.
•
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.
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Periodic Maintenance Procedures
Idle Speed Adjustment
•
Start the engine and warm it up thoroughly.
•
Tilt up the cargo bed.
•
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.
PERIODIC MAINTENANCE 2-13
•
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.
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2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
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.
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Periodic Maintenance Procedures
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.
PERIODIC MAINTENANCE 2-15
•
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]
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2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
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
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
•
Remove:
Cargo Bed (tilt up)
•
Place a suitable container under the carburetor.
•
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
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Periodic Maintenance Procedures
•
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.
PERIODIC MAINTENANCE 2-17
•
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.
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2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Converter System
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.
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Periodic Maintenance Procedures
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.
PERIODIC MAINTENANCE 2-19
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2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
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
Service Limit: 1.9 mm (0.075 in.)
Converter Air Cleaner Element Cleaning/Inspection
NOTE
○
In dusty areas, the element should be cleaned more frequently than the recommended interval.
○
After riding through rain or on muddy roads, the element should be cleaned immediately.
WARNING
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.
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Periodic Maintenance Procedures
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.
PERIODIC MAINTENANCE 2-21
Engine Lubrication System
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
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Lubrication System chapter).
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
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).
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Periodic Maintenance Procedures
Wheels/Tires
Wheels Nuts Tightness Inspection
•
Check the tightness of all the wheel nuts.
If there are loose nut, first loosen by 1/2 turn, then retorque them to the specified torque.
Torque - Wheel Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
○
Tighten the wheel nuts [1]
∼
[4] in a criss-cross pattern.
PERIODIC MAINTENANCE 2-23
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
22 × 9.00-10 DUNLOP KT901 Tubeless
22 × 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.
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2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
After the oil has completely drained out, install the drain plug with a new aluminum gasket, and tighten it.
Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 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]
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Periodic Maintenance Procedures
•
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.
PERIODIC MAINTENANCE 2-25
Brake Fluid Change
•
Tilt up the front cargo hood.
•
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.
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2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
Fill the reservoir with new brake fluid.
•
Temporarily install the reservoir cap.
•
Change the brake fluid as follows:
1. Open bleed valve.
2. Pump brake pedal and hold it.
3. Close bleed valve.
4. Release brake pedal.
•
Tighten:
Torque - Bleed Valves: 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
kgf·m, 30 in·lb)
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.
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Periodic Maintenance Procedures
Brake Master Cylinder Cup and Dust Seal
Replacement
•
Remove the master cylinder (see Master Cylinder Removal in the Brakes chapter).
•
Remove the piston stop bolt [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].
PERIODIC MAINTENANCE 2-27
•
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).
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2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
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]
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Periodic Maintenance Procedures
•
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.
•
Install the removed parts.
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.)
Service Limit: 165.75 mm (6.526 in.)
PERIODIC MAINTENANCE 2-29
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2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
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.
○
Immediately wipe up any brake fluid that spills.
CAUTION
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
•
Unscrew the mounting bolts [B] and take off the front brake wheel cylinder [C].
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Periodic Maintenance Procedures
•
Replace the rear wheel cylinder with a new one.
•
Apply liquid gasket to the hatched area [A].
Sealant - Three Bond: 1109
PERIODIC MAINTENANCE 2-31
•
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.
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2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
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.
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Periodic Maintenance Procedures
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)
PERIODIC MAINTENANCE 2-33
•
Check the operation of the buckle [A].
○
Set the plate [B] in the buckle, and confirm the plate does not come off when pulling it.
○
Set the plate in the buckle, and confirm the plate comes off when the buckle button [C] is pushed.
If operation is not correct, visually inspect the plate.
If the plate is damaged, replace the plate assembly with a new one.
If the plate is not damaged, replace the buckle assembly.
Electrical System
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.
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2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
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.
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Periodic Maintenance Procedures
General Lubrication
•
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
•
Lubricate the points listed below with indicated lubricant.
NOTE
○
Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.
PERIODIC MAINTENANCE 2-35
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.
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2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Bolts, Nuts, and Fasteners
Tightness Inspection
•
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition.
NOTE
○
Check the engine fastener tightness when the engine is 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
Muffler Mounting Bolts
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
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Periodic Maintenance Procedures
Steering
Steering Wheel Mounting Nut
Intermediate Shaft Clamp Bolts
Tie-rod End Nuts and Cotter Pins
Tie-rod End Locknuts
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
PERIODIC MAINTENANCE 2-37
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FUEL SYSTEM 3-1
Fuel System
Exploded View...................................
Specifications ....................................
Throttle Pedal and Cable...................
Inspection..................................
Adjustment ................................
Adjustment ................................
Throttle Cable Installation ............
Throttle Cable Lubrication............
Throttle Cable Inspection .............
Governor Link Mechanism.................
Control Panel Assembly Removal
Installation .................................
Governor Assembly Removal ......
Governor Assembly Installation ...
Governor Assembly Inspection ....
Choke Cable......................................
Choke Knob Free Play Inspection
Adjustment ................................
Choke Cable Installation ..............
Choke Cable Lubrication..............
Choke Cable Inspection...............
Carburetor .........................................
Idle Speed Inspection ..................
Idle Speed Adjustment.................
Table of Contents
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
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3-2 FUEL SYSTEM
Exploded View
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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.
R: Replacement Parts
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
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3-4 FUEL SYSTEM
Exploded View
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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
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3-6 FUEL SYSTEM
Specifications
Item
Throttle Pedal and Cable
Throttle Pedal Free Play
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
– – –
– – –
– – –
– – –
– – –
– – –
– – –
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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
Periodic Maintenance chapter.
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
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3-8 FUEL SYSTEM
Governor Link Mechanism
Control Panel Assembly Removal
•
Tilt up the cargo bed.
•
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.
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Governor Link Mechanism
•
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].
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3-10 FUEL SYSTEM
Governor Link Mechanism
•
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:
Throttle Pedal Free Play Adjustment
Idle Speed Adjustment
•
Install the control panel assembly shroud with pop rivets.
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Governor Link Mechanism
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
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3-12 FUEL SYSTEM
Governor Link Mechanism
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.
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FUEL SYSTEM 3-13
Choke Cable
Choke Knob Free Play Inspection
•
Check that the choke knob returns properly and that the inner cable slides smoothly.
•
Remove:
Guard Plate (see Frame chapter)
•
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:
Guard Plate (see Frame chapter)
•
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.
•
Refer to the General Lubrication in the Periodic Maintenance chapter.
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3-14 FUEL SYSTEM
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.
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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
Periodic Maintenance chapter.
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
•
Remove:
Cargo Bed (tilt up)
Guard Plate (see Frame chapter)
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]
FUEL SYSTEM 3-15
•
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.
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3-16 FUEL SYSTEM
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:
Throttle Pedal Free Play Adjustment
Choke Cable Free Play Adjustment
Idle Speed Adjustment
Carburetor Disassembly
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
•
Remove:
Carburetor (see Carburetor Removal)
Float Chamber Mounting Bolt [A] and Gasket
Float Chamber [B]
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Carburetor
•
Remove:
Pin [A]
Float [B] and Float Valve Needle
•
Remove:
Main Jet [A]
•
Remove:
Pilot Jet Plug [A]
•
Remove:
Pilot Jet [A]
FUEL SYSTEM 3-17
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3-18 FUEL SYSTEM
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]
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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
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.
•
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.
FUEL SYSTEM 3-19
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3-20 FUEL SYSTEM
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 Element (see Air Cleaner Element Removal)
Air Cleaner Ducts [A]
FUEL SYSTEM 3-21
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3-22 FUEL SYSTEM
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
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Fuel Pump
Fuel Pump Removal
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.
•
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 SYSTEM 3-23
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3-24 FUEL SYSTEM
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.
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Fuel Filter
Fuel Filter Removal
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.
•
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 SYSTEM 3-25
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3-26 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
WARNING
Fuel is extremely flammable and can be explosive under certain conditions. Turn the main switch OFF.
Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
•
Remove:
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.
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ENGINE TOP END 4-1
Engine Top End
Table of Contents
4
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4-2 ENGINE TOP END
Exploded View
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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
Muffler Mounting Bolts
EO: Apply engine oil.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specific tightening sequence.
ENGINE TOP END 4-3
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
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4-4 ENGINE TOP END
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.)
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Special Tools
Compression Gauge, 20 kgf/cm²:
57001-221
ENGINE TOP END 4-5
Valve Seat Cutter, 32° 38.5:
57001-1122
Valve Seat Cutter, 45° 32:
57001-1115
Valve Seat Cutter, 45° 35:
57001-1116
Valve Seat Cutter, 32° 35:
57001-1121
Valve Seat Cutter Holder, 7:
57001-1126
Valve Seat Cutter Holder Bar:
57001-1128
Compression Gauge Adapter, M14 × 1.25:
57001-1159
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4-6 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
•
Tilt up the cargo bed.
•
Thoroughly warm up the engine so that the engine oil between the piston and the cylinder wall will help seal compression as it does during normal running.
•
Stop the engine, remove the 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]
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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]
ENGINE TOP END 4-7
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]
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4-8 ENGINE TOP END
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)
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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.
ENGINE TOP END 4-9
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4-10 ENGINE TOP END
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
Service Limit: 0.03 mm (0.001 in.)
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Valves
Valve Clearance Inspection
•
Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Clearance Adjustment
•
Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter.
Valve 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.)
ENGINE TOP END 4-11
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4-12 ENGINE TOP END
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]
Valve Seat Cutter, 45° 32:
57001-1115 [EX]
Valve Seat Cutter, 32° 35:
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]
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ENGINE TOP END 4-13
Valves
Operating Procedures
•
Clean the seat area carefully.
•
Coat the seat with machinist’s dye.
•
Fit a 45° cutter to the holder and slide it into the valve guide.
•
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
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).
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4-14 ENGINE TOP END
Valves
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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
Standard: 35 mm (1.38 in.)
Service Limit: 32.6 mm (1.28 in.)
Valve Head Thickness
•
Measure the thickness [A] of the valve head.
If the valve head thickness is less than the service limit, replace the valve with a new one.
Valve Head Thickness
Standard: 0.4 mm (0.016 in.)
Service Limit: 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
Service Limit: TIR 0.05 mm (0.0020 in.)
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.)
ENGINE TOP END 4-15
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4-16 ENGINE TOP END
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.)
Service Limit: 7.08 mm (0.279 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.)
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Exhaust Pipe and Muffler
Exhaust Pipe Removal
•
Remove:
Right Side Cover (see Frame chapter)
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]
ENGINE TOP END 4-17
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4-18 ENGINE TOP END
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.
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CONVERTER SYSTEM 5-1
Converter System
Table of Contents
5
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5-2 CONVERTER SYSTEM
Exploded View
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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
L: Apply a non-permanent locking agent.
R: Replacement Parts
CONVERTER SYSTEM 5-3
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
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5-4 CONVERTER SYSTEM
Exploded View
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CONVERTER SYSTEM 5-5
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
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5-6 CONVERTER SYSTEM
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.)
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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
CONVERTER SYSTEM 5-7
Drive Pulley Holder:
57001-1620
Drive Pulley Wrench:
57001-1627
Drive Pulley Holder:
57001-1628
Driven Pulley Holder:
57001-1630
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5-8 CONVERTER SYSTEM
Air Cleaner
Air Cleaner Element Removal
•
Remove:
Guard Plate (see Frame chapter)
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 Cleaner Element (see Air Cleaner Element Removal)
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.
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Torque Converter
Torque Converter Removal
•
Remove:
Right Rear Wheel (see Wheels/Tires chapter)
Right Rear Shock Absorber (see Suspension chapter)
Right Side Cover (see Frame chapter)
Cover Bolts [A]
Torque Converter Cover [B] and Duct [C]
CONVERTER SYSTEM 5-9
•
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
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5-10 CONVERTER SYSTEM
Torque Converter
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]
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Torque Converter
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.
CONVERTER SYSTEM 5-11
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5-12 CONVERTER SYSTEM
Torque Converter
•
Install the drive pulley holder [A] (see Torque Converter
Removal).
Special Tool - Drive Pulley Holder: 57001-1620
•
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.
Torque - Drive Pulley Cover Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)
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Torque Converter
•
Set the slit [A] of duct to aligning mark [B].
•
Install:
Torque Converter Cover [C]
Duct [D]
Collar [E]
Cover Bolts [F] (9)
CONVERTER SYSTEM 5-13
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]
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5-14 CONVERTER SYSTEM
Torque Converter
Torque Converter Case Installation
•
Install:
O-rings [A]
Collars [B]
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Torque Converter
•
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)
CONVERTER SYSTEM 5-15
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5-16 CONVERTER SYSTEM
Drive Belt
Drive Belt Removal
•
Refer to the Torque Converter Removal.
Drive Belt Installation
•
Refer to the Torque Converter Installation.
Drive Belt Inspection
•
Refer to the Converter System in the Periodic Maintenance chapter.
Drive Belt Deflection Inspection
•
Refer to the Converter System in the Periodic Maintenance chapter.
Drive Belt Deflection Adjustment
•
Refer to the Converter System in the Periodic Maintenance chapter.
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Drive Pulley
Drive Pulley Removal
•
Refer to the Torque Converter Removal.
Drive Pulley Disassembly
•
Remove:
Drive Pulley (see Torque Converter Removal)
•
Hold the drive pulley holder [A] in a vise.
Special Tool - Drive Pulley Holder: 57001-1628
•
Set the pulley onto the pulley holder.
•
Remove:
Drive Pulley Cover Bolts [A]
Drive Pulley Cover [B]
CONVERTER SYSTEM 5-17
•
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.
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5-18 CONVERTER SYSTEM
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]
Standard: 28.005
∼
28.089 mm (1.103
∼
1.106 in.)
Service Limit: 28.3 mm (1.114 in.)
If the sheave bushing is damaged or worn, replace it.
Sheave Bushing Inside Diameter [A]
Standard: 35.002
∼
35.087 mm (1.378
∼
1.381 in.)
Service Limit: 35.3 mm (1.390 in.)
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Drive Pulley
If the spider shoes [A] are damaged, replace them.
•
Check the spider shoe side clearance (see Spider Shoe
Side Clearance Inspection).
CONVERTER SYSTEM 5-19
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]
Standard: 72 mm (2.83 in.)
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).
Special Tool - Drive Pulley Holder: 57001-1628
Temporarily install:
Dowel Pins (2)
Drive Pulley Cover
Two Bolts (at dowel pins)
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5-20 CONVERTER SYSTEM
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.)
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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.
CONVERTER SYSTEM 5-21
Bushing Installation
•
Press the cover bushing [A] into the cover [B] using the special tool so that the end of bushing is flush with the shoulder [C] in the hole.
Special Tool - Bearing Driver Set: 57001-1129
•
Press the sheave bushing [A] into the movable sheave [B] using the special tool so that the end of bushing is flush with the shoulder [C] in the hole.
Special Tool - Bearing Driver Set: 57001-1129
Drive Pulley 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
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5-22 CONVERTER SYSTEM
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:
Torque - Drive Pulley Cover Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)
•
Clean the surface of the sheaves with an oil-less cleaning fluid.
Drive Pulley Installation
•
Refer to the Torque Converter Installation.
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Driven Pulley
Driven Pulley Removal
•
Refer to the Torque Converter 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
CONVERTER SYSTEM 5-23
•
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]
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5-24 CONVERTER SYSTEM
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]
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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]
CONVERTER SYSTEM 5-25
If the guide bushings [A] are damaged or worn, replace the movable sheave.
Sheave Bushing Inside Diameter
Standard: 38.016
∼
38.100 mm (1.497
∼
1.500 in.)
Service Limit: 38.3 mm (1.51 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.
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5-26 CONVERTER SYSTEM
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.
Special Tool - Bearing Driver Set: 57001-1129
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.
Special Tool - Driven Pulley Holder: 57001-1630
•
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.
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Driven Pulley
•
Put the circlip [A] on the ramp.
•
Install the spring holder [B].
•
Push down the ramp halfway by tightening the nut [C].
CONVERTER SYSTEM 5-27
•
Turn the movable sheave [A] counterclockwise 120° with the driven pulley holder [B].
Special Tool - Driven Pulley Holder: 57001-1630
•
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].
Special Tool - Outside Circlip Pliers: 57001-144
•
Release the movable sheave slowly until it stops naturally.
Driven Pulley Installation
•
Refer to the Torque Converter Installation.
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ENGINE LUBRICATION SYSTEM 6-1
Engine Lubrication System
Table of Contents
6
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6-2 ENGINE LUBRICATION SYSTEM
Exploded View
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ENGINE LUBRICATION SYSTEM 6-3
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
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent to the threads.
R: Replacement Parts
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
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6-4 ENGINE LUBRICATION SYSTEM
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.)
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Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 6-5
1. Oil Pump
2. Rocker Arms
3. Oil Filter
4. Camshaft
5. Relief Valve
6. Crankshaft
7. Oil Screen
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6-6 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury.
Oil Level Inspection
NOTE
○
If the vehicle has just been used, wait 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.
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ENGINE LUBRICATION SYSTEM 6-7
Engine Oil and Oil Filter
•
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
Maintenance chapter.
Oil Filter Replacement
•
Refer to the Oil Filter Replacement section in the Periodic
Maintenance chapter.
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6-8 ENGINE LUBRICATION SYSTEM
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.)
Service Limit: 0.20 mm (0.00787 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.)
Service Limit: 40.47 mm (1.5933 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.)
Service Limit: 9.94 mm (0.3913 in.)
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ENGINE LUBRICATION SYSTEM 6-9
Oil Pump, Relief Valve
•
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
Standard: 40.680
∼
40.701 mm (1.6016
∼
1.6024 in.)
Service Limit: 40.801 mm (1.6063 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.)
Service Limit: 10.16 mm (0.4000 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
Standard: 12.695
∼
12.715 mm (0.4998
∼
0.5006 in.)
Service Limit: 12.645 mm (0.4978 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
Standard: 12.735
∼
12.750 mm (0.5014
∼
0.5020 in.)
Service Limit: 12.811 mm (0.5044 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]
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6-10 ENGINE LUBRICATION SYSTEM
Oil Pump, Relief Valve
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.)
Service Limit: 15.7 mm (0.618 in.)
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ENGINE LUBRICATION SYSTEM 6-11
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.
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6-12 ENGINE LUBRICATION SYSTEM
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)
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ENGINE REMOVAL/INSTALLATION 7-1
Engine Removal/Installation
Table of Contents
7
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7-2 ENGINE REMOVAL/INSTALLATION
Exploded View
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Exploded View
No.
Fastener
1 Engine Mounting Bolts and Nuts
2 Connecting Plate Bolts (M8)
3 Connecting Plate Bolts (M10)
L: Apply a non-permanent locking agent.
ENGINE REMOVAL/INSTALLATION 7-3
N·m
24.5
28
55
Torque kgf·m
2.5
2.9
5.6
ft·lb
18
21
41
Remarks
L
L
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7-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Alignment Jig:
57001-1631
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ENGINE REMOVAL/INSTALLATION 7-5
Engine Removal/Installation
Engine Removal
•
Disconnect:
Battery Terminal Leads (see Electrical System chapter)
•
Remove:
Cargo Bed
Guard Plate (see Frame chapter)
Exhaust Pipe (see Engine Top End chapter)
Torque Converter Case (see Converter System chapter)
Connecting Plate (see Transmission Case in the Transmission chapter)
Carburetor (see Fuel System 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]
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7-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
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].
•
Apply a non-permanent locking agent:
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.
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Engine Removal/Installation
ENGINE REMOVAL/INSTALLATION 7-7
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ENGINE BOTTOM END 8-1
Engine Bottom End
Table of Contents
8
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8-2 ENGINE BOTTOM END
Exploded View
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ENGINE BOTTOM END 8-3
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
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
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
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8-4 ENGINE BOTTOM END
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
Crankcase Cover 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
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ENGINE BOTTOM END 8-5
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
Crankcase Cover 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.)
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8-6 ENGINE BOTTOM END
Special Tools
Piston Ring Compressor Grip:
57001-1095
Bearing Driver Set:
57001-1129
Piston Ring Compressor Belt, 80
∼
91:
57001-1320
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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.
Special Tool - Bearing Driver Set: 57001-1129
•
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.)
ENGINE BOTTOM END 8-7
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)
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8-8 ENGINE BOTTOM END
Camshaft and Tappets
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.
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Camshaft and Tappets
•
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
kgf·m, 61 in·lb)
•
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].
ENGINE BOTTOM END 8-9
•
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.
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8-10 ENGINE BOTTOM END
Camshaft and Tappets
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. )
Service Limit: 19.94 mm (0.785 in.)
Crankcase Cover Side Camshaft Journal Diameter
Standard: 49.959
∼
49.975 mm (1.9669
∼
1.9675 in. )
Service Limit: 49.93 mm (1.966 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)
Standard: 20.000
∼
20.013 mm (0.7874
∼
0.7879 in. )
Service Limit: 20.07 mm (0.790 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)
Standard: 50.000
∼
50.025 mm (1.9685
∼
1.9695 in. )
Service Limit: 50.09 mm (1.972 in.)
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Cylinders and Pistons
Piston Removal
•
Remove:
Crankcase Cover (see Crankcase Cover Removal)
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.
ENGINE BOTTOM END 8-11
•
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.
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8-12 ENGINE BOTTOM END
Cylinders and Pistons
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.
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Cylinders and Pistons
•
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
kgf·m, 52 in·lb)
•
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.
ENGINE BOTTOM END 8-13
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8-14 ENGINE BOTTOM END
Cylinders and Pistons
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.
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Cylinders and Pistons
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
Standard: 18.995
∼
19.000 mm (0.7478
∼
0.7480 in.)
Service Limit: 18.96 mm (0.746 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
Standard: 19.004
∼
19.015 mm (0.7482
∼
0.7486 in.)
Service Limit: 19.08 mm (0.751 in.)
ENGINE BOTTOM END 8-15
•
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
Standard: 19.010
∼
19.021 mm (0.7484
∼
0.7489 in.)
Service Limit: 19.06 mm (0.750 in.)
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8-16 ENGINE BOTTOM END
Cylinders and Pistons
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
Standard: 81.935
∼
81.955 mm (3.2258
∼
3.2266 in.)
Service Limit: 81.79 mm (3.220 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.)
Service Limit: 82.10 mm (3.232 in.)
Cylinder Bore Out-Round
Service Limit: 0.05 mm (0.0020 in.)
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Crankshaft and Connecting Rods
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.
ENGINE BOTTOM END 8-17
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8-18 ENGINE BOTTOM END
Crankshaft and Connecting Rods
•
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.)
Service Limit: 27.0 mm (1.063 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.)
Service Limit: 28.4 mm (1.112 in.)
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Crankshaft and Connecting Rods
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
Standard: 43.004
∼
43.015 mm (1.6931
∼
1.6935 in.)
Service Limit: 43.04 mm (1.694 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
Standard: 42.957
∼
42.970 mm (1.6912
∼
1.6917 in.)
Service Limit: 42.94 mm (1.691 in.)
ENGINE BOTTOM END 8-19
•
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
Service Limit: TIR 0.05 mm (0.002 in.)
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
Standard: 34.955
∼
34.980 mm (1.3762
∼
1.3772 in.)
Service Limit: 34.93 mm (1.375 in.)
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8-20 ENGINE BOTTOM END
Crankshaft and Connecting Rods
•
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.)
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Balancer Shaft
Balancer Shaft Removal
•
Remove:
Crankcase Cover (see Crankcase Cover Removal)
Balancer Shaft [A]
ENGINE BOTTOM END 8-21
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.)
Service Limit 31.935 mm (1.257 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.)
Service Limit 32.06 mm (1.262 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.)
Service Limit 32.06 mm (1.262 in.)
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8-22 ENGINE BOTTOM END
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.
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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].
ENGINE BOTTOM END 8-23
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.
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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 ...
Inspection..................................
Shift Rod Bending ........................
Shift Fork Ear and Shifter Groove
Wear..........................................
Mechanism Inspection ..............
(KAF400-A/C) .................................
Adjustment ................................
Lubrication.................................
2WD/4WD Shift Cable Inspection
Table of Contents
Removal ....................................
Inspection..................................
Mechanism .....................................
Adjustment ................................
Lubrication.................................
Differential Shift Cable Inspection
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
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9-2 TRANSMISSION
Exploded View
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Exploded View
1. Differential Shift Cable
2. Transmission Cable
3. 2WD/4WD Shift Cable (KAF400-A/C)
R: Replacement Parts
TRANSMISSION 9-3
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9-4 TRANSMISSION
Exploded View
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Exploded View
No.
Fastener
1 Transmission Cable Holder Bolts
2 Connecting Plate Bolts (M8)
3 Connecting Plate Bolts (M10)
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
L: Apply a non-permanent locking agent.
O: Apply engine oil.
R: Replacement Parts
TRANSMISSION 9-5
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
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9-6 TRANSMISSION
Exploded View
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TRANSMISSION 9-7
Exploded View
No.
Fastener
Torque kgf·m
5.8
ft·lb
42
Remarks
1 Differential Gear Housing Bolts
N·m
57 L
L: Apply a non-permanent locking agent.
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)
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9-8 TRANSMISSION
Specifications
Item
Transmission Oil
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.)
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Special Tools
Outside Circlip Pliers:
57001-144
Oil Seal & Bearing Remover:
57001-1058
Bearing Driver Set:
57001-1129
TRANSMISSION 9-9
Socket Wrench, Hex 41:
57001-1402
Alignment Jig:
57001-1631
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9-10 TRANSMISSION
Transmission Oil
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
Maintenance chapter.
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Transmission Case
Transmission Case Removal
•
Drain:
Transmission Oil (see Transmission Oil Change in the
Periodic Maintenance chapter)
•
Remove:
Cargo Bed (see Frame chapter)
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)
Torque Converter Case (see Converter System chapter)
•
Remove:
Control Panel Assembly [A] (see Fuel System chapter)
Transmission Shift Shaft Lever [B] and Bracket [C]
TRANSMISSION 9-11
•
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)
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9-12 TRANSMISSION
Transmission Case
•
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)
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Transmission Case
•
Apply a non-permanent locking agent:
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
kgf·m, 36 ft·lb)
Rear Axle Bracket Bolts: 24.5 N·m (2.5 kgf·m, 18 ft·lb)
•
Remove the alignment jig.
TRANSMISSION 9-13
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]
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9-14 TRANSMISSION
Transmission Case
•
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)
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Transmission Case
•
Using the socket wrench [A] remove the bearing holder
[B].
Special Tool - Socket Wrench, Hex 41: 57001-1402
TRANSMISSION 9-15
•
Remove:
Circlip [A] of Transmission Shaft [B]
Special Tool - Outside Circlip Pliers: 57001-144
•
Remove:
Collar [C]
Sprocket [D]
•
Remove:
Needle Bearing [A]
Spacer [B]
Shifter [C]
•
Remove:
Circlip
Special Tool - Outside Circlip Pliers: 57001-144
•
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]
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9-16 TRANSMISSION
Transmission Case
•
Remove:
Needle Bearing [A]
Washer [B]
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Transmission Case
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)
TRANSMISSION 9-17
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9-18 TRANSMISSION
Transmission Case
•
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]
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Transmission Case
○
Apply a non-permanent locking agent:
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)
Special Tool - Socket Wrench, Hex 41: 57001-1402
•
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)
TRANSMISSION 9-19
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9-20 TRANSMISSION
Transmission Case
•
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
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Transmission Case
•
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]
TRANSMISSION 9-21
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9-22 TRANSMISSION
Transmission Case
•
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.
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Transmission Case
•
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 9-23
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9-24 TRANSMISSION
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]
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Transmission and Shift Mechanism
Transmission Shift Cable Inspection
•
With the cable disconnected at both ends, the cable should move freely within the cable housing.
If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable.
TRANSMISSION 9-25
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.)
Service Limit: 5.8 mm (0.228 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.)
Service Limit: 6.25 mm (0.2460 in.)
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9-26 TRANSMISSION
Transmission and Shift Mechanism
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]
Standard: 190.50
∼
190.97 mm (7.500
∼
7.518 in.)
Service Limit: 193.4 mm (7.614 in.)
[A] Force
[C] 1st Pin
[D] 2nd Pin
[E] 21st Pin
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2WD/4WD Shift Mechanism (KAF400-A/C)
2WD/4WD Shift Cable Adjustment
•
Put the shift lever [A] in the 2WD position.
TRANSMISSION 9-27
•
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.
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9-28 TRANSMISSION
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.
If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable.
2WD/4WD Shift Mechanism Removal
•
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]
If they are damaged or worn excessively, replace them.
Shifter Block Outside Diameter
Standard: 13.95
∼
14.00 mm (0.549
∼
0.551 in.)
Service Limit: 13.8 mm (0.543 in.)
Shifter Groove Width
Standard: 14.0
∼
14.2 mm (0.551
∼
0.559 in.)
Service Limit: 14.3 mm (0.563 in.)
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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].
TRANSMISSION 9-29
•
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.
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9-30 TRANSMISSION
Differential Gears and Shift Mechanism
Differential Shift Cable Inspection
•
With the cable disconnected at both ends, the cable should move freely [A] within the cable housing.
If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable.
Differential Shift Mechanism Removal
•
Remove:
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]
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Differential Gears and Shift Mechanism
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)
TRANSMISSION 9-31
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]
If they are damaged or worn excessively, replace them.
Shift Shaft Pin Diameter [A]
Standard: 8.4
∼
8.6 mm (0.331
∼
0.339 in.)
Service Limit: 8.3 mm (0.327 in.)
Shifter Groove Width [B]
Standard: 9.0
∼
9.1 mm (0.354
∼
0.358 in.)
Service Limit: 9.2 mm (0.362 in.)
Differential Gear Removal
•
Remove:
Transmission Case (split, see Transmission Case Disassembly)
Differential Gear Assembly [A]
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9-32 TRANSMISSION
Differential Gears and Shift Mechanism
•
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
•
Apply a non-permanent locking agent:
Differential Gear Housing Bolts
•
Tighten:
Torque - Differential Gear Housing Bolts: 57 N·m (5.8
kgf·m, 42 ft·lb)
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Differential Gears and Shift Mechanism
Differential Gear Inspection
•
Visually inspect the differential gears.
Replace the gears as a set if either gear is damaged.
TRANSMISSION 9-33
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9-34 TRANSMISSION
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.
Special Tool - Bearing Driver Set: 57001-1129
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.
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Transmission Sectional Figure
TRANSMISSION 9-35
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9-36 TRANSMISSION
Transmission Sectional Figure
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Transmission Sectional Figure
TRANSMISSION 9-37
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9-38 TRANSMISSION
Transmission Sectional Figure
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WHEELS/TIRES 10-1
Wheels/Tires
Table of Contents
10
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10-2 WHEELS/TIRES
Exploded View
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WHEELS/TIRES 10-3
Exploded View
No.
Fastener
1 Wheel Nuts
R: Replacement Parts
W: Apply a soap and water solution, or water.
N·m
34
Torque kgf·m
3.5
ft·lb
25
Remarks
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10-4 WHEELS/TIRES
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
DUNLOP KT869, Tubeless
22 × 9.00 – 10
DUNLOP KT901, Tubeless
22 × 11.00 – 10
DUNLOP KT869, Tubeless
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.)
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Special Tool
Jack:
57001-1238
WHEELS/TIRES 10-5
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10-6 WHEELS/TIRES
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.
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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.
WHEELS/TIRES 10-7
If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary.
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10-8 WHEELS/TIRES
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).
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WHEELS/TIRES 10-9
Tires
Tire Removal
•
Remove:
Wheel (see Wheel Removal)
Valve Core (let out the air)
•
Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [A].
This helps the tire beads slip off the rim flanges.
CAUTION
Do not lubricate the 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.
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10-10 WHEELS/TIRES
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.
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FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Front Final Gear Case (KAF400-A/C)
Front Final Gear Case Oil Level
Inspection .................................
Change......................................
Front Final Gear Case Removal ..
Front Final Gear Case Installation
Disassembly..............................
Front Final Gear Case Assembly.
Differential Unit Disassembly .......
Differential Unit Assembly............
LSD Clutch Torque Inspection .....
LSD Clutch Plate Inspection ........
Pinion Gear Unit Disassembly .....
Pinion Gear Unit Assembly ..........
Adjustment ................................
Bevel Gear Inspection..................
Differential Gear Inspection .........
Ball Bearing Inspection ................
Oil Seal Inspection .......................
Bevel Gear Case (KAF400-A/C)........
Driven Bevel Gear Removal ........
Driven Bevel Gear Installation .....
Driven Bevel Gear Disassembly ..
Driven Bevel Gear Assembly .......
Drive Bevel Gear Removal ..........
Drive Bevel Gear Installation .......
Bevel Gear Adjustment ...............
Bevel Gear Inspection..................
Ball Bearing/Oil Seal Inspection...
Propeller Shafts (KAF400-A/C) .........
Front Propeller Shaft Removal.....
Front Propeller Shaft Installation..
Rear Propeller Shaft Removal .....
Rear Propeller Shaft Installation ..
Propeller Shaft Inspection............
Axles..................................................
(KAF400-A/C)............................
(KAF400-A/C)............................
Front Axle Removal (KAF400-B) .
(KAF400-B) ...............................
Rear Axle Removal ......................
Rear Axle Installation ...................
Axle Inspection.............................
(KAF400-A/C)............................
Replacement (KAF400-A/C) .....
Ball Bearing Inspection ................
Grease Seal Inspection................
11
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11-2 FINAL DRIVE
Exploded View
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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.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
O: Apply oil.
R: Replacement Parts
FINAL DRIVE 11-3
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
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11-4 FINAL DRIVE
Exploded View
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FINAL DRIVE 11-5
Exploded View
No.
1
2
3
4
5
6
7
8
Fastener
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
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.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil. (The weight ratio of the mixture between engine oil and disulfide grease is 10 : 1)
O: Apply oil.
R: Replacement Parts
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11-6 FINAL DRIVE
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
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
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Special Tools
Bearing Puller:
57001-135
Outside Circlip Pliers:
57001-144
Socket Wrench:
57001-1283
Socket Wrench, Hex 48:
57001-1401
Pinion Gear Holder:
57001-1632
Snap Ring Guide, 20:
57001-1633
FINAL DRIVE 11-7
Snap Ring Guide, 22:
57001-1634
Bevel Gear Holder:
57001-1638
Bevel Gear Holder:
57001-1639
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11-8 FINAL DRIVE
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
kgf·m, 22 ft·lb)
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
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Front Final Gear Case (KAF400-A/C)
•
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.
FINAL DRIVE 11-9
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]
Special Tool - Outside Circlip Pliers [B]: 57001-144
•
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].
Special Tool - Socket Wrench, Hex 48: 57001-1401
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11-10 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
•
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]
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Front Final Gear Case (KAF400-A/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]
FINAL DRIVE 11-11
○
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)
Special Tool - Socket Wrench, Hex 48: 57001-1401
○
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)
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11-12 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
•
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)
Special Tool - Outside Circlip Pliers: 57001-144
Differential Unit Disassembly
•
Remove:
Differential Unit (see Front Final Gear Case Disassembly)
Differential Gear Housing Bolts [A]
Differential Gear Unit [B]
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FINAL DRIVE 11-13
Front Final Gear Case (KAF400-A/C)
•
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]
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11-14 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
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].
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FINAL DRIVE 11-15
Front Final Gear Case (KAF400-A/C)
•
Apply a non-permanent locking agent:
Differential Gear Housing Bolts [A]
•
Finger-tighten the all bolts first.
•
Tighten:
Torque - Differential Gear Housing Bolts: 49 N·m (5.0
kgf·m, 36 ft·lb)
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.)
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11-16 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
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)
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Front Final Gear Case (KAF400-A/C)
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
FINAL DRIVE 11-17
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11-18 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
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).
○
Change the thickness a little at a time.
•
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).
○
Change the thickness a little at a time.
•
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)
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Front Final Gear Case (KAF400-A/C)
Front Final Gear Case (Backlash-Related Parts)
FINAL DRIVE 11-19
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
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11-20 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
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
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Front Final Gear Case (KAF400-A/C)
Tooth Contact Adjustment
•
Clean any dirt and oil off the bevel gear teeth.
•
Apply checking compound to 4 or 5 teeth on the pinion gear.
NOTE
○
Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear.
○
The checking compound must be smooth and firm, with the consistency of tooth paste.
○
Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use one of these for checking the bevel gears.
•
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.
FINAL DRIVE 11-21
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11-22 FINAL DRIVE
Front Final Gear Case (KAF400-A/C)
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.
Heel [A] Bottom [B] Top [C] Toe [D] Ring Gear [E] Pinion Gear [F]
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.
Heel [A] Bottom [B] Top [C] Toe [D] Ring Gear [E] Pinion Gear [F]
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Front Final Gear Case (KAF400-A/C)
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.
Ball Bearing Inspection
•
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.
•
Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.
Oil Seal Inspection
•
Visually inspect the oil seal.
Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
FINAL DRIVE 11-23
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11-24 FINAL DRIVE
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]
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Bevel Gear Case (KAF400-A/C)
•
Pry open the toothed washer tab [A] on the driven bevel gear slotted nut [B] with a small chisel.
FINAL DRIVE 11-25
•
Unscrew the driven bevel gear slotted nut.
Special Tools - Bevel Gear Holder [A]: 57001-1638
Socket Wrench [B]: 57001-1283
•
Remove:
Driven Bevel Gear Slotted Nut
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)
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11-26 FINAL DRIVE
Bevel Gear Case (KAF400-A/C)
•
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]
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Bevel Gear Case (KAF400-A/C)
•
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.
FINAL DRIVE 11-27
○
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
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11-28 FINAL DRIVE
Bevel Gear Case (KAF400-A/C)
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:
Special Tool - Bevel Gear Holder: 57001-1638
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.
Property of www.SmallEngineDiscount.com - Not for Resale
Bevel Gear Case (KAF400-A/C)
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)
Special Tool - Bevel Gear Holder: 57001-1638
•
Clean any dirt and oil off the bevel gear teeth.
•
Install:
Drive Bevel Gear (see Drive Bevel Gear Installation)
Driven Bevel Gear (see Driven Bevel Gear Installation)
Bevel Gear Holder [B]
Special Tool - Bevel Gear Holder: 57001-1639
•
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).
Change the thickness a little at a time.
•
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)
FINAL DRIVE 11-29
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11-30 FINAL DRIVE
Bevel Gear Case (KAF400-A/C)
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
Property of www.SmallEngineDiscount.com - Not for Resale
Bevel Gear Case (KAF400-A/C)
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.
•
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.
•
Inspect the oil seals.
Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
FINAL DRIVE 11-31
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11-32 FINAL DRIVE
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.
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Propeller Shafts (KAF400-A/C)
•
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.
FINAL DRIVE 11-33
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11-34 FINAL DRIVE
Propeller Shafts (KAF400-A/C)
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]
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Propeller Shafts (KAF400-A/C)
•
Push the universal joint [A] forward fully, and remove the rear end from the bevel gear shaft [B].
•
Remove:
Rear Propeller Shaft [C]
FINAL DRIVE 11-35
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
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11-36 FINAL DRIVE
Propeller Shafts (KAF400-A/C)
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.
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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]
FINAL DRIVE 11-37
•
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)
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11-38 FINAL DRIVE
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.
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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]
FINAL DRIVE 11-39
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]
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11-40 FINAL DRIVE
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].
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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.
FINAL DRIVE 11-41
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.
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11-42 FINAL DRIVE
Axles
•
Remove the steel balls [A].
•
Slide the cage [B] toward the outboard joint.
•
Remove:
Circlip [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
•
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.
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Axles
•
Install:
Circlip [A]
Special Tool - Outside Circlip Pliers: 57001-144
•
Slide the cage [B] on the inner race and install the steel balls [C].
•
Apply the special grease [A] to the steel balls and cage.
FINAL DRIVE 11-43
•
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].
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11-44 FINAL DRIVE
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.
Ball Bearing Inspection
•
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.
•
Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.
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Axles
Grease Seal Inspection
•
Visually inspect the grease seals.
Replace if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damage.
FINAL DRIVE 11-45
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BRAKES 12-1
Brakes
Table of Contents
12
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12-2 BRAKES
Exploded View
Front Brake
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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.
L: Apply a non-permanent locking agent.
R: Replacement Parts
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
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12-4 BRAKES
Exploded View
Rear Brake
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Exploded View
No.
1 Brake Pipe Nipples
2 Brake Pipe Mounting Bolt
3
4
Bleed Valves
Fastener
Wheel Cylinder Mounting Bolts
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).
L: Apply a non-permanent locking agent.
R: Replacement Parts
ft·lb
13
17
71 in·lb
106 in·lb
53 in·lb
25
224
BRAKES 12-5
Remarks
L
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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.)
– – –
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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
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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 quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
Brake Fluid Level Inspection
•
Refer to the Brakes in the Periodic Maintenance chapter.
Brake Fluid Change
•
Refer to the Brakes in the Periodic Maintenance chapter.
Brake Line Air Bleeding
•
Tilt up the front cargo hood.
•
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.
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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.
•
Install the removed parts.
Torque - Master Cylinder Reservoir Cap: 3.4 N·m (0.35
kgf·m, 30 in·lb)
BRAKES 12-9
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12-10 BRAKES
Brake Pedal and Master Cylinder
Brake Pedal Play Inspection
•
Refer to the Brakes in the Periodic Maintenance chapter.
Master Cylinder Removal
•
Remove:
Front Cargo Compartment (see Frame chapter)
Cotter Pin [A] and Pin [B]
Brake Hose Banjo Bolts [C]
Brake Pipe Nipple [D] (unscrew)
•
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:
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.
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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
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12-12 BRAKES
Brake Hoses and Pipes
Brake Hose and Pipe Inspection
•
Refer to the Brakes in the Periodic Maintenance chapter.
Brake Hose and Pipe Replacement
•
Refer to the Brakes in the Periodic Maintenance chapter.
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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)
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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
•
Refer to the Brakes in the Periodic Maintenance chapter.
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Brake Panel Assemblies
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)
•
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 (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
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12-16 BRAKES
Brake Panel Assemblies
(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
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 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.)
•
Immediately wipe up any brake fluid that spills.
CAUTION
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
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Brake Panel Assemblies
•
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
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12-18 BRAKES
Brake Panel Assemblies
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]
Property of www.SmallEngineDiscount.com - Not for Resale
Brake Panel Assemblies
•
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)
Property of www.SmallEngineDiscount.com - Not for Resale
12-20 BRAKES
Brake Panel Assemblies
•
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
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.
•
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.
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BRAKES 12-21
Brake Panel Assemblies
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)
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12-22 BRAKES
Parking Brake Lever and Cables
Parking Brake Lever Travel Adjustment
•
Refer to the Brakes in the Periodic Maintenance chapter.
Parking Brake Cable Lubrication/Inspection
•
Refer to the General Lubrication in the Periodic Maintenance chapter.
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SUSPENSION 13-1
Suspension
Table of Contents
13
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13-2 SUSPENSION
Exploded View
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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
R: Replacement Parts
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
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13-4 SUSPENSION
Specifications
Item
Rear Shock Absorbers
Spring preload setting position
Standard
3rd position
Service Limit
(Usable Range)
1
∼
5 positions
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Special Tool
Outside Circlip Pliers:
57001-144
Steering Stem Nut Wrench:
57001-1100
SUSPENSION 13-5
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13-6 SUSPENSION
Struts and Rear Shock Absorbers
Strut (Front Shock Absorber) Removal
•
Remove:
Front Cargo Compartment (see Frame chapter)
Front Wheel (see Wheels/Tires chapter)
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)
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Struts and Rear Shock Absorbers
•
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.
○
It should be within 30 degree.
○
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
Struts and Rear Shock Absorbers
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.
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Front Suspension Arms
Front Suspension Arm Removal
•
Remove:
Front Cargo Compartment (see Frame chapter)
Front Wheel (see Wheels/Tires chapter)
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].
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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
kgf·m, 65 ft·lb)
Front Suspension Arm Joint Nut: 78.5 N·m (8.0
kgf·m, 58 ft·lb)
•
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.
○
It should be within 30 degree.
○
Loosen once and tighten again when the slit goes past the nearest hole.
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.
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SUSPENSION 13-11
Swingarm
Swingarm Removal
•
Remove:
Cargo Bed (see Frame chapter)
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.
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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]
Special Tool - Outside Circlip Pliers [B]: 57001-144
○
Using a press, remove the swingarm joint [C].
•
Replace:
Swingarm Joint
Circlip
•
Using a press, install the swingarm joint.
•
Install:
Circlip
Special Tool - Outside Circlip Pliers: 57001-144
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STEERING 14-1
Steering
Table of Contents
14
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14-2 STEERING
Exploded View
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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.
R: Replacement Parts
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
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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
– – –
– – –
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Special Tools
Inside Circlip Pliers:
57001-143
Outside Circlip Pliers:
57001-144
Bearing Driver Set:
57001-1129
Knuckle Joint Remover:
57001-1619
STEERING 14-5
Knuckle Joint Driver:
57001-1640
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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):
Front Cargo Compartment (see Frame chapter)
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].
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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
kgf·m, 18 ft·lb)
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
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14-8 STEERING
Steering Gear Assembly
Steering Gear Assembly Removal
•
Remove:
Front Cargo Compartment (see Frame chapter)
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)
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Steering Gear Assembly
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
kgf·m, 29 ft·lb)
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
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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
kgf·m, 58 ft·lb)
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.
○
It should be within 30 degree.
○
Loosen once and tighten again when the slit goes past the nearest hole.
•
Install the removed parts.
•
Check:
Toe-in of Front Wheels (see Wheels/Tires chapter)
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Steering Knuckles
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.
Special Tool - Bearing Driver Set: 57001-1129
Knuckle Bearing Installation
•
Press in the bearing until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
•
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]
Special Tool - Outside Circlip Pliers [B]: 57001-144
•
Remove the knuckle joint [A] using a press.
Special Tool - Knuckle Joint Remover [B]: 57001-1619
STEERING 14-11
Property of www.SmallEngineDiscount.com - Not for Resale
14-12 STEERING
Steering Knuckles
Knuckle Joint Installation
•
Press the knuckle joint [A] until it is bottomed.
Special Tool - Knuckle Joint Driver [B]: 57001-1640
•
Replace the circlip with a new one.
Special Tool - Outside Circlip Pliers: 57001-144
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FRAME 15-1
Frame
Table of Contents
15
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15-2 FRAME
Exploded View
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Exploded View
AD: Apply adhesive agent.
G: Apply grease.
FRAME 15-3
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15-4 FRAME
Exploded View
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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
AD: Apply adhesive agent.
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
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15-6 FRAME
Exploded View
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Exploded View
AD: Apply adhesive agent.
G: Apply grease.
L: Apply Locktite 242 Blue.
FRAME 15-7
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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)
Property of www.SmallEngineDiscount.com - Not for Resale
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
Property of www.SmallEngineDiscount.com - Not for Resale
15-10 FRAME
Control Panel
Glove Compartment Removal
•
Remove:
Control Panel (see Control Panel Removal)
Screws [A]
Glove Compartment [B]
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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:
Screws [A] and Collars
•
Remove:
Screws [A] and Collars
Quick Rivet [B]
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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]
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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]
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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:
Cargo Bed Mounting Pins
•
Install:
Cargo Bed
Cargo Bed Mounting Pins
Snap Pins
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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
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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
kgf·m, 32 ft·lb)
Washers [C]
Nuts [D]
Rear Bar Removal
•
Remove:
Front Bar Mounting Bolts (Upper) [A], Washers and Nuts
•
Tilt up the cargo bed.
•
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
kgf·m, 32 ft·lb)
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]
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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
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15-18 FRAME
Guard and Cover
Front Guard Removal
•
Remove:
Screws [A] and Collars
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]
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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]
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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]
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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]
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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.
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ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View...................................
Wiring Diagram (KAF400-A/C) ..........
Wiring Diagram (KAF400-B)..............
Specifications ....................................
Special Tools .....................................
Parts Location....................................
Precautions........................................
Electrical Wiring.................................
Wiring Inspection .........................
Battery ...............................................
Battery Removal ..........................
Battery Installation .......................
Electrolyte Level Inspection .........
Inspection..................................
Charging Condition Inspection.....
Initial Charging .............................
Ordinary Charging........................
Battery Test Charging ..................
Charging System ...............................
Removal ....................................
Installation .................................
Inspection..................................
Stator Coil Resistance .................
Regulator/Rectifier Inspection......
Ignition System ..................................
Spark Plug Removal ....................
Spark Plug Installation .................
Spark Plug Cleaning/Inspection...
Spark Plug Gap Inspection ..........
Ignition Coil Removal ...................
Ignition Coil Installation ................
Ignition Coil inspection .................
Electric Starter System ......................
Starter Motor Removal.................
Starter Motor Installation..............
Starter Solenoid Inspection..........
Starter Motor Inspection...............
Starter Motor Disassembly...........
Starter Motor Assembly ...............
Starter Motor Brush Inspection ....
Brush Spring Inspection...............
Armature Inspection.....................
Yoke Assembly Inspection ...........
Pinion Clutch Inspection ..............
Starter Circuit Relay Inspection ...
Lighting System .................................
Headlight Beam Adjustment ........
Headlight Bulb Replacement .......
Tail/Brake Light Replacement ......
Light Switch Bulb Replacement ...
Indicator Light Bulb Replacement 16-46
Switches ............................................
Brake Light Switch Inspection......
Inspection (KAF400-A/C) ..........
Indicator Control Unit Inspection
(KAF400-A/C)............................
Switch Inspection .........................
Fuses.................................................
Fuse Removal..............................
Fuse Installation...........................
Fuse Inspection............................
16
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16-2 ELECTRICAL SYSTEM
Exploded View
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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
ELECTRICAL SYSTEM 16-3
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
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16-4 ELECTRICAL SYSTEM
Exploded View
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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
ELECTRICAL SYSTEM 16-5
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
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16-6 ELECTRICAL SYSTEM
Wiring Diagram (KAF400-A/C)
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Wiring Diagram (KAF400-A/C)
ELECTRICAL SYSTEM 16-7
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16-8 ELECTRICAL SYSTEM
Wiring Diagram (KAF400-B)
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Wiring Diagram (KAF400-B)
ELECTRICAL SYSTEM 16-9
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16-10 ELECTRICAL SYSTEM
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.)
– – –
– – –
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Special Tools
Spark Plug Wrench, Hex 21:
57001-110
ELECTRICAL SYSTEM 16-11
Hand Tester:
57001-1394
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16-12 ELECTRICAL SYSTEM
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]
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Parts Location
Ignition Coil [A]
Alternator [B]
Oil Temperature Sensor [C] (KAF400-A/C)
Neutral Position Switch [D]
Reverse Position Switch [E] (Europe Model)
ELECTRICAL SYSTEM 16-13
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)
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16-14 ELECTRICAL SYSTEM
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]
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Precautions
Male Connectors [B]
ELECTRICAL SYSTEM 16-15
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16-16 ELECTRICAL SYSTEM
Electrical Wiring
Wiring Inspection
•
Visually inspect the wiring for signs of burning, fraying, etc.
If any wiring is poor, replace the damaged wiring.
•
Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
• is damaged, replace it.
Check the wiring for continuity.
○
Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
○
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.
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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].
ELECTRICAL SYSTEM 16-17
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
•
Refer to the Electrical System in the Periodic Maintenance chapter.
Charging Condition Inspection
•
Refer to the Electrical System in the Periodic Maintenance chapter.
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16-18 ELECTRICAL SYSTEM
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.
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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)
ELECTRICAL SYSTEM 16-19
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16-20 ELECTRICAL SYSTEM
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
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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]
ELECTRICAL SYSTEM 16-21
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16-22 ELECTRICAL SYSTEM
Charging System
Alternator Rotor and Stator Removal
•
Tilt up the cargo bed.
•
Remove:
Left Rear Wheel (see Wheels/Tires chapter)
Carburetor (see Fuel System 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.
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Charging System
•
Remove:
Ignition Coil Lead Connector [A] (disconnect)
Ignition Coil Bolts [B]
Ignition Coil [C]
ELECTRICAL SYSTEM 16-23
•
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]
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16-24 ELECTRICAL SYSTEM
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.
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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)
ELECTRICAL SYSTEM 16-25
•
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)
•
Install the removed parts.
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
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16-26 ELECTRICAL SYSTEM
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.
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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.
•
Check G/W1 and G/W2 terminals respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
ELECTRICAL SYSTEM 16-27
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.
•
Check G/W1 and G/W2 terminals respectively.
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.
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16-28 ELECTRICAL SYSTEM
Charging System
Charging System Circuit
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. 30 A Fuse
6. Load
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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:
Guard Plate (see Frame chapter)
Spark Plug Cap [A]
•
Remove the spark plug using the plug wrench [B].
Special Tool - Spark Plug Wrench, Hex 21: 57001-110
ELECTRICAL SYSTEM 16-29
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
Maintenance chapter.
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]
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16-30 ELECTRICAL SYSTEM
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.
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Ignition System
Ignition System Circuit
ELECTRICAL SYSTEM 16-31
1. Ignition Switch
2. Ignition Coil
3. Spark Plug
4. Alternator Rotor
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16-32 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal
•
Remove:
Torque Converter Case (see Converter System chapter)
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.
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Electric Starter System
•
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)
ELECTRICAL SYSTEM 16-33
Starter Solenoid Inspection
NOTE
○
Be sure the battery is fully charged.
•
Remove:
Starter Motor (see Starter Motor Removal)
•
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]
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16-34 ELECTRICAL SYSTEM
Electric Starter System
•
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 (see Starter Motor Removal)
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.
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Electric Starter System
•
Pull the armature [A] from the yoke [B].
ELECTRICAL SYSTEM 16-35
•
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].
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16-36 ELECTRICAL SYSTEM
Electric Starter System
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.
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Electric Starter System
•
Engage the hook on the starter solenoid with the hook [A] on the pinion gear fork [B].
ELECTRICAL SYSTEM 16-37
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.)
Service Limit: 6 mm (0.236 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.)
Service Limit: 0.2 mm (0.008 in.)
Bad [A]
Segment [B]
Good [C]
0.2 mm (0.008 in.) limit [D]
Mica [E]
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16-38 ELECTRICAL SYSTEM
Electric Starter System
•
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.)
Service Limit: 27 mm (1.063 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
Service Limit: 0.4 mm (0.016 in.)
•
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.
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Electric Starter System
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
(
∞)
ELECTRICAL SYSTEM 16-39
•
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]
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16-40 ELECTRICAL SYSTEM
Electric Starter System
•
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]
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Electric Starter System
Electric Starter Circuit
ELECTRICAL SYSTEM 16-41
1. Ignition Switch
2. Starter Motor
3. Starter Circuit Relay (Neutral)
4. Neutral Switch
5. Starter Circuit Relay (Brake)
6. Brake Switch
7. Battery
8. 30 A Fuse
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16-42 ELECTRICAL SYSTEM
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.
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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.
ELECTRICAL SYSTEM 16-43
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16-44 ELECTRICAL SYSTEM
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.
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Lighting System
•
Install the removed parts.
Nuts [A]
Dampers [B]
Collars [C]
Washers [D]
Bolts [E]
Collar [F]
Screws [G]
ELECTRICAL SYSTEM 16-45
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.
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16-46 ELECTRICAL SYSTEM
Lighting System
Light Switch Bulb Replacement
•
Remove:
Front Cargo Compartment (see Frame chapter)
•
Turn the socket [A] counterclockwise, and pull it with the bulb.
•
Pull the bulb [A] out of the socket.
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 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
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
Do not use bulb rated for greater wattage than the specified value.
•
Install:
Bulb
Lens [A]
Light Assembly [B]
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Lighting System
Lighting System Circuit
ELECTRICAL SYSTEM 16-47
1. Light Switch
2. Ignition Switch
3. Headlights
4. Position Lights
5. Brake/Tail Lights
6. Brake Switch
7. 30 A Fuse
8. Battery
9. Parking Brake Light Switch
10. Parking Brake Light
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16-48 ELECTRICAL SYSTEM
Switches
Brake Light Switch Inspection
•
Refer to Brake Light Switch Inspection in the Periodic
Maintenance chapter.
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.
ELECTRICAL SYSTEM 16-49
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
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16-50 ELECTRICAL SYSTEM
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)
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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.
ELECTRICAL SYSTEM 16-51
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APPENDIX 17-1
Appendix
Table of Contents
17
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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:
Piston ring/groove clearance excessive
Fuel level too high
Cylinder head warped
Float valve worn or stuck open
Cylinder head gasket damaged
Starting technique faulty
Valve spring broken or weak
(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:
Spark plug dirty, broken, or maladjusted
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
Spark plug incorrect
Brake dragging
Ignition coil trouble
Poor Running or No Power at High Speed:
Ignition switch shorted
Firing incorrect:
Wiring shorted or open
Spark plug dirty, broken, or maladjusted
Fuse blown
Spark plug cap shorted or not in good con-
Compression Low:
tact
Spark plug loose
Spark plug incorrect
Cylinder head not sufficiently tightened
Ignition coil trouble down
No valve clearance
Fuel/air mixture incorrect:
Property of www.SmallEngineDiscount.com - Not for Resale
APPENDIX 17-3
Troubleshooting Guide
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
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Miscellaneous:
Throttle valve won’t fully open
Brake dragging
Overheating
Engine oil level too high
Engine oil viscosity too high
Front final gear case oil viscosity too high
(KAF400-A/C)
Drive train trouble
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level too low
Air cleaner clogged, poorly sealed, or missing
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Converter and/or belt excessive heating:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
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
Drive or driven pulley sheave dirty or worn
Drive pulley spring broken or weak
Converter engagement speed too low:
Drive pulley spring broken or weak
Converter engagement speed too high:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
Drive pulley weight doesn’t move smoothly
Drive pulley movable sheave doesn’t move smoothly
Drive or driven pulley movable sheave bush worn
Drive pulley weight or roller worn
Shifting too quickly:
Drive pulley spring weak
Driven pulley spring weak or incorrectly installed (too loose)
Shifting too slowly:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
Drive pulley weight doesn’t move smoothly
Drive pulley movable sheave doesn’t move smoothly
Driven pulley spring incorrect installed (too tight)
Driven pulley movable sheave doesn’t move smoothly
Gear Shifting Faulty:
Doesn’t go into gear:
Shift arm bent or seized
Gear stuck on the shaft
Shift cable maladjusted
Shift cable lubrication inadequate
Shift cable damaged
Jumps out of gear:
Shifter groove worn
Gear dogs worn
Shift arm positioning bolt spring weak or broken
Shift block worn
17-4 APPENDIX
Troubleshooting Guide
Transmission shaft, and/or gear splines worn
Shift cable maladjusted
Overshifts:
Shift arm positioning bolt spring weak or broken
Shift cable maladjusted
Abnormal Engine Noise:
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin holes worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Rocker arm push rod runout excessive
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stuck
Piston seizure or damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine 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
Troubleshooting Guide
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
Property of www.SmallEngineDiscount.com - Not for Resale
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)
Cable, Wire, and Hose Routing
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.)
Property of www.SmallEngineDiscount.com - Not for Resale
17-8 APPENDIX
Cable, Wire, and Hose Routing
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
12. 2WD/4WD Shift Cable (KAF400-A/C)
13. Throttle Cable
Cable, Wire, and Hose Routing
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
9. Differential Lock Shift Cable
10. Choke Cable
11. Transmission Shift Cable
12. 2WD/4WD Shift Cable (KAF400-A/C)
13. Throttle Cable
17-10 APPENDIX
Cable, Wire, and Hose Routing
1. Main Harness
2. Differential Lock Shift Cable
3. Choke Cable
4. Transmission Shift Cable
5. 2WD/4WD Shift Cable (KAF400-A/C)
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
Property of www.SmallEngineDiscount.com - Not for Resale
Cable, Wire, and Hose Routing
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
7. Transmission Shift Cable
8. Throttle Cable
9. Starter Motor
10. (+) Lead
11. Push the lead and change the route.
12. 10 mm (0.39 in.)
Property of www.SmallEngineDiscount.com - Not for Resale
17-12 APPENDIX
Cable, Wire, and Hose Routing
1. Accessory Fuse 10 A
2. Fuse 30 A
3. Battery
4. Engine Ground Lead
5. Starter Motor Lead
6. Frame Ground Lead
7. Parking Brake Light Switch
8. Starter Circuit Relay (Brake)
9. Starter Circuit Relay (Neutral)
10. Regulator/rectifier
11. Oil Temperature Warning Indicator Control Unit (KAF400-A/C)
Property of www.SmallEngineDiscount.com - Not for Resale
Cable, Wire, and Hose Routing
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
Property of www.SmallEngineDiscount.com - Not for Resale
17-14 APPENDIX
Cable, Wire, and Hose Routing
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)
Property of www.SmallEngineDiscount.com - Not for Resale
Cable, Wire, and Hose Routing
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.
Property of www.SmallEngineDiscount.com - Not for Resale
17-16 APPENDIX
Cable, Wire, and Hose Routing
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
Property of www.SmallEngineDiscount.com - Not for Resale
Cable, Wire, and Hose Routing
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.)
Property of www.SmallEngineDiscount.com - Not for Resale
17-18 APPENDIX
Cable, Wire, and Hose Routing
1. Air Cleaner
2. Clamp
3. Air Duct
4. Carburetor
5. Clamp
6. Clamp
7. Drain Tube
8. Clamp
Property of www.SmallEngineDiscount.com - Not for Resale
Cable, Wire, and Hose Routing
APPENDIX 17-19
1. Band
2. Front Final Gear Case Breather Hose
3. Grommet
4. Clamp
5. Front Final Gear Case
Property of www.SmallEngineDiscount.com - Not for Resale
17-20 APPENDIX
Cable, Wire, and Hose Routing
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
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Key Features
- Powerful 617cc engine provides ample power for hauling and towing.
- CVT transmission offers smooth and effortless shifting.
- 4WD with locking front differential ensures maximum traction in all conditions.
- Independent front and rear suspension provides a comfortable ride over rough terrain.
- Hydraulic disc brakes provide excellent stopping power.
- Comfortable seating for two with plenty of legroom and headroom
- Large cargo bed and towing capacity make it easy to transport heavy loads.
- Numerous storage compartments and accessories allow for customization and convenience.
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Frequently Answers and Questions
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What type of suspension does the Kawasaki MULE 610 4X4 2011 have?
What type of brakes does the Kawasaki MULE 610 4X4 have?
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Table of contents
- 1 tables
- 6 LIST OF ABBREVIATIONS
- 22 Units of Mass
- 22 Units of Volume
- 22 Units of Force
- 22 Units of Length
- 22 Units of Torque
- 22 Units of Pressure
- 22 Units of Speed
- 22 Units of Power
- 30 Basic Torque for General Fasteners of Engine Parts
- 30 Basic Torque for General Fasteners of Frame Parts
- 34 Throttle Pedal Free Play
- 34 Idle Speed
- 35 Idle Speed
- 39 Valve Clearance (when cold)
- 40 Belt Width
- 40 Belt Deflection
- 41 shims
- 42 Wear Shoe Width
- 43 Engine Oil
- 44 Transmission Oil
- 45 Tire Tread Depth
- 45 Standard Tire
- 46 Front Final Gear Case Oil
- 48 Brake Pedal Free Play
- 51 Brake Drum Inside Diameter
- 52 Brake Shoe Lining thickness
- 53 Parking Brake Lever Travel
- 54 Steering Wheel Free Play
- 55 Spark Plug Gap
- 56 Specific Gravity
- 56 Brake Light Switch Timing
- 70 Idle Speed
- 73 Choke Knob Free Play
- 92 Cylinder Compression
- 95 Rocker Arm Push Rod Runout
- 96 Cylinder Head Warp
- 97 Valve Seating Surface Outside Diameter
- 97 Valve Seating Surface Width Standard
- 101 Valve Spring Free Length
- 101 Valve Head Thickness
- 101 Valve Stem Bend
- 101 Valve Stem Diameter
- 102 Valve Guide Inside Diameter
- 102 Valve/Guide Clearance (Wobble Method)
- 114 Driven Pulley
- 115 Drive Pulley
- 122 Cover Bushing Inside Diameter [A]
- 122 Sheave Bushing Inside Diameter [A]
- 123 Spring Free Length [A]
- 124 Shoe Side Clearance
- 129 Sheave Bushing Inside Diameter
- 129 Spring Free Length [A]
- 140 Inner and Outer Rotor Clearance
- 140 Outer Rotor Outside Diameter
- 140 Outer Rotor Thickness
- 141 Pump Housing Inside Diameter
- 141 Pump Housing Depth
- 141 Pump Shaft Outside Diameter
- 141 Pump Shaft Bearing Inside Diameter
- 142 Relief Valve Spring Free Length
- 162 Cam Lobe Height
- 162 Crankcase Side Camshaft Journal Diameter
- 162 Crankcase Cover Side Camshaft Journal Diameter
- 162 Camshaft Bearing Inside Diameter (Crankcase)
- 162 Camshaft Bearing Inside Diameter (Crankcase Cover)
- 166 Piston Ring/Groove Clearance
- 166 Piston Ring Thickness
- 167 Piston Ring End Gap
- 167 Piston Pin Outside Diameter
- 167 Piston Pin Hole Inside Diameter
- 167 Connecting Rod Small End Inside Diameter
- 168 Piston Diameter
- 168 Cylinder Inside Diameter
- 168 Cylinder Bore Out-Round
- 170 Connecting Rod Bend
- 170 Connecting Rod Twist
- 170 Connecting Rod Big End Width
- 170 Crankpin Width
- 171 Connecting Rod Big End Inside Diameter
- 171 Crankpin Outside Diameter
- 171 Crankshaft Runout
- 171 Crankcase Side Crankshaft Main Journal Diameter
- 172 Crankshaft Main Bearing Inside Diameter (Crankcase Side)
- 173 Balancer Shaft Journal Diameter
- 173 Balancer Shaft Bearing Inside Diameter (Crankcase)
- 173 Balancer Shaft Bearing Inside Diameter (Crankcase cover)
- 201 Shift Fork Ear Thickness
- 201 Shifter Groove Width [A]
- 202 Reverse Chain 20-Link Length [B]
- 204 Shifter Block Outside Diameter
- 204 Shifter Groove Width
- 207 Shift Shaft Pin Diameter [A]
- 207 Shifter Groove Width [B]
- 220 Toe-in of Front Wheels
- 220 Tie-rod Length (distance between flange end and locknut)
- 223 Maximum Tire Air Pressure (to seat beads when cold)
- 224 Tire Air Pressure (when cold)
- 239 LSD Clutch Torque
- 239 Outside Friction Plate Thickness [A]
- 239 Inside Friction Plate Thickness [B]
- 242 Bevel Gear Backlash
- 253 Bevel Gear Backlash
- 254 Drive Gear Shims [4]
- 265 Standard Length of Assembling:
- 268 Standard Length of Assembling:
- 278 Recommended Brake Fluid
- 299 Spring Action
- 358 Battery Troubleshooting Guide
- 363 Regulator/Rectifier Output Voltage
- 364 Stator Coil Resistance
- 368 Ignition Coil Air Gap
- 368 Ignition Coil Winding Resistance
- 371 Testing Solenoid
- 372 Testing Starter Motor
- 375 Carbon Brush Length
- 375 Commutator Groove Depth
- 376 Commutator Outside Diameter
- 376 Commutator Runout
- 376 Armature Winding Resistance
- 376 Commutator to Shaft Resistance
- 377 Positive Brush to Ground Resistance
- 377 Negative Brush to Ground Resistance
- 378 Testing Relay
- 386 Oil Temperature Sensor Resistance
- 387 Internal Resistance Unit: kΩ
- 1 toc
- 6 Read OWNER'S MANUAL before operating.
- 7 EMISSION CONTROL INFORMATION
- 7 1.
- 7 2.
- 8 PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (United States Mo
- 9 Foreword
- 11 General Information
- 12 Before starting to perform an inspection service or carry out a
- 12 Battery Ground
- 12 Edges of Parts
- 12 Solvent
- 12 Cleaning vehicle before disassembly
- 13 Arrangement and Cleaning of Removed Parts
- 13 Storage of Removed Parts
- 13 Inspection
- 13 Replacement Parts
- 13 Assembly Order
- 14 Tightening Sequence
- 14 Tightening Torque
- 14 Force
- 14 Gasket, O-ring
- 14 Liquid Gasket, Locking Agent
- 15 Press
- 15 Ball Bearing and Needle Bearing
- 15 Oil Seal, Grease Seal
- 15 Circlips, Cotter Pins
- 16 Lubrication
- 16 Direction of Engine Rotation
- 16 Electrical Wires
- 17 KAF400-A1 Left Side View
- 17 KAF400-A1 Right Side View
- 18 KAF400-B1 Left Side View
- 18 KAF400-B1 Right Side View
- 22 Prefixes for Units
- 22 Units of Temperature:
- 23 Periodic Maintenance
- 24 The scheduled maintenance must be done in accordance with this c
- 26 The following tables list the tightening torque for the major fa
- 33 Inside Circlip Pliers:
- 34 Fuel System
- 34 Throttle Pedal Free Play Inspection
- 34 Throttle Pedal Free Play Adjustment
- 34 Idle Speed Inspection
- 35 Idle Speed Adjustment
- 35 Air Cleaner Element Cleaning
- 36 Fuel Hoses And Connections Inspection
- 37 Fuel Hoses Replacement
- 37 Fuel Filter Replacement
- 38 Fuel System Cleanliness Inspection
- 38 Engine Top End
- 38 Valve Clearance Inspection
- 39 Valve Clearance Adjustment
- 39 Torque -
- 39 Spark Arrester Cleaning
- 40 Converter System
- 40 Drive Belt Inspection
- 40 Drive Belt Deflection Inspection
- 41 Drive Belt Deflection Adjustment
- 41 Torque -
- 41 Converter Driven Pulley Shoe Inspection
- 42 Converter Air Cleaner Element Cleaning/Inspection
- 43 Converter Dust or Water Drain
- 43 Engine Lubrication System
- 43 Engine Oil Change
- 43 Torque -
- 44 Oil Filter Replacement
- 44 Special Tool -
- 44 Special Tool -
- 44 Torque -
- 44 Transmission
- 44 Transmission Oil Change
- 44 Torque -
- 45 Wheels/Tires
- 45 Wheels Nuts Tightness Inspection
- 45 Torque -
- 45 Tire Wear Inspection
- 45 Final Drive (KAF400-A/C models)
- 45 Front Final Gear Case Oil Change
- 46 Torque -
- 46 Torque -
- 46 Brakes
- 46 Brake Fluid Level Inspection
- 47 Brake Fluid Change
- 48 Torque -
- 48 Torque -
- 48 Brake Pedal Play Inspection
- 48 Torque -
- 49 Brake Master Cylinder Cup and Dust Seal Replacement
- 49 Special Tool -
- 49 Torque -
- 50 Brake Hose and Pipe Inspection
- 50 Brake Hose and Pipe Replacement
- 51 Torque -
- 51 Torque -
- 51 Brake Wear Inspection
- 52 Brake Wheel Cylinder Assembly Replacement
- 53 Sealant -
- 53 Torque -
- 53 Parking Brake Lever Inspection
- 54 Steering
- 54 Steering Inspection
- 54 Steering Joint Dust Boot Inspection
- 55 Frame
- 55 Seat Belt Inspection
- 55 Torque -
- 55 Electrical System
- 55 Spark Plug Cleaning/Inspection
- 55 Spark Plug Gap Inspection
- 55 Electrolyte Level Inspection
- 56 Electrolyte Specific Gravity Inspection
- 56 Brake Light Switch Inspection
- 57 General Lubrication
- 57 Pivots and Points: Lubricate with Grease.
- 57 Cables: Lubricate with Rust Inhibitor.
- 57 Cables: Lubricate with Motor Oil.
- 58 Bolts, Nuts, and Fasteners
- 58 Tightness Inspection
- 58 Nut, Bolt, and Fasteners to be checked
- 61 Fuel System
- 67 Throttle Pedal Free Play Inspection
- 67 Throttle Pedal Free Play Adjustment
- 67 Full Throttle Pedal Position Adjustment
- 67 Throttle Cable Installation
- 67 Throttle Cable Lubrication
- 67 Throttle Cable Inspection
- 68 Control Panel Assembly Removal
- 68 Control Panel Assembly Installation
- 68 Torque -
- 72 Governor Assembly Removal
- 72 Governor Assembly Installation
- 72 Governor Assembly Inspection
- 73 Choke Knob Free Play Inspection
- 73 Choke Knob Free Play Adjustment
- 73 Choke Cable Installation
- 73 Choke Cable Lubrication
- 74 Choke Cable Inspection
- 75 Idle Speed Inspection
- 75 Idle Speed Adjustment
- 75 Fuel System Cleanliness Inspection
- 75 Carburetor Removal
- 76 Carburetor Installation
- 76 Torque -
- 76 Carburetor Disassembly
- 78 Carburetor Assembly
- 78 Torque -
- 79 Carburetor Cleaning
- 79 Carburetor Inspection
- 80 Pilot Screw Setting
- 81 Air Cleaner Element Removal
- 81 Air Cleaner Element Installation
- 81 Air Cleaner Housing Removal
- 82 Air Cleaner Housing Installation
- 82 Torque -
- 82 Air Cleaner Housing Dust and/or Water Installation
- 83 Fuel Pump Removal
- 83 Fuel Pump Installation
- 83 Torque -
- 83 Fuel Pump Inspection
- 85 Fuel Filter Removal
- 85 Fuel Filter Installation
- 85 Fuel Filter Inspection
- 86 Fuel Tank Removal
- 86 Fuel Tank Installation
- 86 Fuel Tank Cleaning/Inspection
- 87 Engine Top End
- 91 Compression Gauge, 20 kgf/cm :
- 92 Cylinder Compression Measurement
- 92 Special Tools -
- 92 Cylinder Head Removal
- 93 Cylinder Head Installation
- 94 Torque -
- 94 Torque -
- 95 Push Rod Inspection
- 95 Valve Mechanism Removal/Installation
- 95 Rocker Arm Inspection
- 96 Cylinder Head Warp
- 97 Valve Clearance Inspection
- 97 Valve Clearance Adjustment
- 97 Valve Seat Inspection
- 98 Valve Seat Repair
- 98 Special Tools -
- 101 Valve Spring Free Length
- 101 Valve Head Thickness
- 101 Valve Stem Bend
- 101 Valve Stem Diameter
- 102 Valve Guide Inside Diameter
- 102 Measuring Valve/Guide Clearance (Wobble Method)
- 103 Exhaust Pipe Removal
- 103 Muffler Removal
- 104 Exhaust Pipe and Muffler Installation
- 104 Torque -
- 104 Exhaust Pipe and Muffler Inspection
- 104 Spark Arrester Cleaning
- 105 Converter System
- 111 Outside Circlip Pliers:
- 112 Air Cleaner Element Removal
- 112 Air Cleaner Element Cleaning/Inspection
- 112 Air Cleaner Housing Removal
- 113 Torque Converter Removal
- 113 Special Tool -
- 113 Torque -
- 113 Special Tool -
- 114 Special Tools -
- 114 Special Tool -
- 114 Torque Converter Installation
- 115 Special Tools -
- 115 Torque -
- 116 Special Tool -
- 116 Torque -
- 116 Torque -
- 117 Torque Converter Case Removal
- 118 Torque Converter Case Installation
- 119 Torque -
- 120 Drive Belt Removal
- 120 Drive Belt Installation
- 120 Drive Belt Inspection
- 120 Drive Belt Deflection Inspection
- 120 Drive Belt Deflection Adjustment
- 121 Drive Pulley Removal
- 121 Drive Pulley Disassembly
- 121 Special Tool -
- 121 Special Tool -
- 122 Drive Pulley Inspection
- 123 Spider Shoe Side Clearance Adjustment
- 123 Special Tool -
- 125 Bushing Installation
- 125 Special Tool -
- 125 Special Tool -
- 125 Drive Pulley Assembly
- 125 Torque -
- 125 Special Tool -
- 126 Special Tool -
- 126 Torque -
- 126 Torque -
- 126 Drive Pulley Installation
- 127 Driven Pulley Removal
- 127 Driven Pulley Disassembly
- 127 Special Tool -
- 127 Special Tool -
- 129 Driven Pulley Inspection
- 129 Converter Driven Pulley Shoe Inspection
- 130 Bushing Installation
- 130 Special Tool -
- 130 Driven Pulley Assembly
- 130 Torque -
- 130 Special Tool -
- 131 Special Tool -
- 131 Special Tool -
- 131 Driven Pulley Installation
- 133 Engine Lubrication System
- 138 WARNING
- 138 Oil Level Inspection
- 139 Engine Oil Change
- 139 Oil Filter Replacement
- 140 Oil Pump Removal
- 140 Oil Pump Installation
- 140 Oil Pump Inspection
- 141 Relief Valve Removal
- 142 Relief Valve Installation
- 142 Relief Valve Inspection
- 143 Oil Screen Removal
- 143 Oil Screen Installation
- 143 Oil Screen Cleaning/Inspection
- 144 Oil Temperature Sensor Removal
- 144 Oil Temperature Sensor Installation
- 144 Torque -
- 145 Engine Removal/Installation
- 148 Alignment Jig:
- 149 Engine Removal
- 150 Engine Installation
- 150 Special Tool -
- 150 Torque -
- 153 Engine Bottom End
- 158 Piston Ring Compressor Grip:
- 159 Crankcase Cover Removal
- 159 Crankcase Cover Assembly
- 159 Special Tool -
- 159 Crankcase Cover Installation
- 159 Torque -
- 160 Camshaft, Tappet Removal
- 160 Camshaft, Tappet Installation
- 161 Torque -
- 161 Camshaft Disassembly
- 161 Camshaft Assembly
- 161 Camshaft Inspection
- 162 Camshaft Bearing/Journal Wear
- 163 Piston Removal
- 164 Piston Installation
- 165 Special Tools -
- 165 Torque -
- 165 Piston Cleaning
- 166 Piston Ring and Ring Groove Wear
- 167 Piston Ring End Gap
- 167 Piston Pin, Piston Pin Hole, and Connecting Rod Wear
- 168 Piston Diameter
- 168 Cylinder Inside Diameter
- 169 Connecting Rod Removal
- 169 Connecting Rod Installation
- 169 Crankshaft Removal
- 169 Crankshaft Installation
- 169 Cleaning/Inspection
- 170 Connecting Rod Bend/Twist
- 170 Connecting Rod Big End/Crankpin Width Wear
- 171 Connecting Rod Big End Bearing/Crankpin Wear
- 171 Crankshaft Runout
- 171 Crankshaft Main Bearing/Journal Wear
- 173 Balancer Shaft Removal
- 173 Balancer Shaft Installation
- 173 Balancer Shaft Bearing/Journal Wear
- 174 The function of the breather is to create a negative pressure in
- 175 Breather Valve Removal
- 175 Breather Valve Installation
- 175 Torque -
- 175 Breather Valve Inspection
- 177 Transmission
- 185 Outside Circlip Pliers:
- 186 CAUTION
- 186 Transmission Oil Level Inspection
- 186 Transmission Oil Change
- 187 Transmission Case Removal
- 188 Transmission Case Installation
- 189 Special Tool -
- 189 Torque -
- 189 Torque -
- 189 Transmission Case Disassembly
- 191 Special Tool -
- 191 Special Tool -
- 191 Special Tool -
- 193 Transmission Case Assembly
- 193 Torque -
- 195 Torque -
- 195 Special Tool -
- 195 Torque -
- 198 Special Tool -
- 199 Sealant -
- 199 Torque -
- 200 Transmission Cable Installation
- 200 Torque -
- 201 Transmission Shift Cable Inspection
- 201 Shift Rod Bending
- 201 Shift Fork Ear and Shifter Groove Wear
- 202 Transmission and Shift Mechanism Inspection
- 203 2WD/4WD Shift Cable Adjustment
- 203 2WD/4WD Shift Cable Lubrication
- 204 2WD/4WD Shift Cable Inspection
- 204 2WD/4WD Shift Mechanism Removal
- 204 2WD/4WD Shift Mechanism Inspection
- 205 Differential Shift Cable Adjustment
- 205 Differential Shift Cable Lubrication
- 206 Differential Shift Cable Inspection
- 206 Differential Shift Mechanism Removal
- 207 Differential Shift Mechanism Installation
- 207 Torque -
- 207 Torque -
- 207 Differential Shift Mechanism Inspection
- 207 Differential Gear Removal
- 208 Differential Gear Installation
- 208 Torque -
- 209 Differential Gear Inspection
- 210 Bearing Replacement
- 210 Special Tools -
- 210 Special Tool -
- 210 Ball Bearing Inspection
- 210 Needle Bearing Inspection
- 210 Oil Seal Inspection
- 215 Wheels/Tires
- 219 Jack:
- 220 Toe-in is the amount that the front wheels are closer together i
- 220 Toe-in Adjustment
- 220 Torque -
- 221 Wheel Removal
- 221 Special Tool -
- 221 Wheel Installation
- 221 Torque -
- 221 Wheel (Rim) Inspection
- 222 Wheel (Rim) Replacement
- 223 Tire Removal
- 223 Tire Installation
- 224 Tire Wear Inspection
- 225 Final Drive
- 231 Bearing Puller:
- 232 Front Final Gear Case Oil Level Inspection
- 232 Torque -
- 232 Front Final Gear Case Oil Change
- 232 Front Final Gear Case Removal
- 233 Front Final Gear Case Installation
- 233 Front Final Gear Case Disassembly
- 233 Special Tool -
- 233 Special Tool -
- 235 Front Final Gear Case Assembly
- 235 Torque -
- 235 Torque -
- 235 Special Tool -
- 236 Sealant -
- 236 Torque -
- 236 Special Tool -
- 236 Differential Unit Disassembly
- 238 Differential Unit Assembly
- 239 Torque -
- 239 LSD Clutch Torque Inspection
- 239 LSD Clutch Plate Inspection
- 240 Pinion Gear Unit Disassembly
- 240 Special Tool -
- 240 Special Tool -
- 240 Pinion Gear Unit Assembly
- 240 Torque -
- 241 Front Final Bevel Gear Adjustment
- 241 Torque -
- 241 Special Tool -
- 242 Special Tool -
- 243 Front Final Gear Case (Backlash-Related Parts)
- 246 Correct Tooth Contact Pattern: No adjustment is required.
- 246 Incorrect Tooth Contact Patterns (Example 1)
- 246 Incorrect Tooth Contact Patterns (Example 2)
- 247 Bevel Gear Inspection
- 247 Differential Gear Inspection
- 247 Ball Bearing Inspection
- 247 Oil Seal Inspection
- 248 Driven Bevel Gear Removal
- 248 Driven Bevel Gear Installation
- 248 Torque -
- 248 Driven Bevel Gear Disassembly
- 249 Special Tools -
- 249 Driven Bevel Gear Assembly
- 249 Special Tools -
- 249 Torque -
- 250 Special Tool -
- 251 Special Tool -
- 251 Drive Bevel Gear Removal
- 251 Special Tool -
- 252 Drive Bevel Gear Installation
- 252 Special Tool -
- 252 Torque -
- 252 Bevel Gear Adjustment
- 253 Special Tool -
- 253 Special Tool -
- 253 Torque -
- 254 Bevel Gear Case (Backlash-Related Parts)
- 255 Bevel Gear Inspection
- 255 Ball Bearing/Oil Seal Inspection
- 256 Front Propeller Shaft Removal
- 256 Front Propeller Shaft Installation
- 258 Rear Propeller Shaft Removal
- 259 Rear Propeller Shaft Installation
- 259 Torque -
- 260 Propeller Shaft Inspection
- 261 Front Axle Removal (KAF400-A/C)
- 261 Front Axle Installation (KAF400-A/C)
- 261 Front Axle Removal (KAF400-B)
- 261 Front Axle Installation (KAF400-B)
- 261 Torque -
- 262 Rear Axle Removal
- 262 Rear Axle Installation
- 262 Axle Inspection
- 262 Dust Boot Inspection (KAF400-A/C)
- 263 Front Axle Joint Boot Replacement (KAF400-A/C)
- 266 Special Tool -
- 267 Special Tool -
- 268 Ball Bearing Inspection
- 269 Grease Seal Inspection
- 271 Brakes
- 272 Front Brake
- 274 Rear Brake
- 277 Clutch Spring Compressor:
- 278 Brake Fluid Recommendation
- 278 Brake Fluid Level Inspection
- 278 Brake Fluid Change
- 278 Brake Line Air Bleeding
- 279 Torque -
- 279 Torque -
- 280 Brake Pedal Play Inspection
- 280 Master Cylinder Removal
- 280 Master Cylinder Installation
- 280 Torque -
- 280 Master Cylinder Disassembly/Assembly
- 281 Master Cylinder Inspection
- 282 Brake Hose and Pipe Inspection
- 282 Brake Hose and Pipe Replacement
- 283 Brake Drum Removal
- 283 Special Tool -
- 283 Special Tools -
- 283 Brake Drum Installation
- 283 Special Tool -
- 283 Special Tool -
- 283 Torque -
- 283 Torque -
- 284 Brake Drum Wear
- 285 Brake Panel Assy Removal
- 285 Brake Panel Assy Installation
- 285 Sealant -
- 286 Sealant -
- 286 Bond -
- 286 Torque -
- 286 Brake Panel Disassembly
- 288 Brake Panel Assembly
- 289 Torque -
- 290 Wheel Cylinder Removal/Installation
- 290 Wheel Cylinder Assembly
- 290 Wheel Cylinder Inspection
- 290 Brake Shoe Lining Wear
- 291 Brake Shoe Spring Inspection
- 291 Grease Seal Replacement
- 291 Special Tool -
- 291 Special Tool -
- 291 Special Tool -
- 291 Torque -
- 292 Parking Brake Lever Travel Adjustment
- 292 Parking Brake Cable Lubrication/Inspection
- 293 Suspension
- 297 Outside Circlip Pliers:
- 298 Strut (Front Shock Absorber) Removal
- 298 Strut (Front Shock Absorber) Installation
- 298 Torque -
- 299 Rear Shock Absorber Preload Adjustment
- 299 Special Tool -
- 299 Rear Shock Absorber Removal
- 299 Rear Shock Absorber Installation
- 299 Torque -
- 300 Rear Shock Absorber Inspection
- 301 Front Suspension Arm Removal
- 302 Front Suspension Arm Installation
- 302 Torque -
- 302 Front Suspension Arm Inspection
- 303 Swingarm Removal
- 303 Swingarm Installation
- 304 Torque -
- 304 Swingarm Inspection
- 304 Swingarm Joint Replacement
- 304 Special Tool -
- 304 Special Tool -
- 305 Steering
- 309 Inside Circlip Pliers:
- 310 Steering Wheel Free Play Inspection
- 310 Steering Wheel Centering
- 310 Torque -
- 310 Steering Wheel and Steering Shaft Removal
- 311 Steering Wheel and Steering Shaft Installation
- 311 Torque -
- 312 Steering Gear Assembly Removal
- 312 Steering Gear Assembly Installation
- 312 Torque -
- 313 Steering Gear Preload Adjustment
- 313 Torque -
- 313 Tie-rod Length Adjustment
- 313 Dust Boot Inspection
- 314 Steering Knuckle Removal
- 314 Steering Knuckle Installation
- 314 Torque -
- 315 Knuckle Bearing Removal
- 315 Special Tool -
- 315 Special Tool -
- 315 Knuckle Bearing Installation
- 315 Special Tool -
- 315 Special Tool -
- 315 Knuckle Joint Removal
- 315 Special Tool -
- 315 Special Tool -
- 316 Knuckle Joint Installation
- 316 Special Tool -
- 316 Special Tool -
- 317 Frame
- 324 Seat Removal
- 324 Seat Installation
- 324 Seat Belt Removal
- 324 Seat Belt Installation
- 324 Torque -
- 325 Control Panel Removal
- 326 Glove Compartment Removal
- 327 Front Cargo Hood Removal
- 327 Front Cargo Compartment Removal
- 328 Front Cargo Compartment Installation
- 329 Cargo Bed Removal
- 330 Cargo Bed Assembly
- 330 Cargo Bed Installation
- 331 Cargo Bed Latch Position Inspection
- 331 Cargo Bed Latch Position Adjustment
- 332 Front Bar Removal
- 332 Front Bar Installation
- 332 Torque -
- 332 Rear Bar Removal
- 332 Rear Bar Installation
- 332 Torque -
- 333 Front Fender Installation
- 334 Front Guard Removal
- 334 Front Guard Installation
- 334 Floor Center Panel Removal
- 335 Floor Center Panel Installation
- 335 Front Final Gear Case Guard Removal
- 335 Front Final Gear Case Guard Installation
- 335 Bottom Guard Removal
- 336 Bottom Guard Installation
- 336 Transmission Case Guard Removal
- 336 Transmission Case Guard Installation
- 336 Center Cover Removal
- 336 Center Cover Installation
- 337 Side Covers Removal
- 337 Side Covers Installation
- 337 Guard Plate Removal
- 338 Guard Plate Installation
- 339 Electrical System
- 349 Spark Plug Wrench, Hex 21:
- 350 Oil Temperature Warning Indicator Light [A]
- 352 There are a number of important precautions that are musts when
- 354 Wiring Inspection
- 355 Battery Removal
- 355 Battery Installation
- 355 Electrolyte Level Inspection
- 355 Electrolyte Specific Gravity Inspection
- 355 Charging Condition Inspection
- 356 Initial Charging
- 357 Ordinary Charging
- 358 Battery Charging Rate/Time Table
- 359 Battery Test Charging
- 359 Special Tool -
- 360 Alternator Rotor and Stator Removal
- 362 Alternator Rotor and Stator Installation
- 362 Torque -
- 363 Torque -
- 363 Torque -
- 363 Charging System Operational Inspection
- 364 Stator Coil Resistance
- 364 Regulator/Rectifier Inspection
- 366 Charging System Circuit
- 367 WARNING
- 367 Spark Plug Removal
- 367 Special Tool -
- 367 Spark Plug Installation
- 367 Torque -
- 367 Spark Plug Cleaning/Inspection
- 367 Spark Plug Gap Inspection
- 367 Ignition Coil Removal
- 368 Ignition Coil Installation
- 368 Torque -
- 368 Ignition Coil inspection
- 368 Special Tool -
- 369 Ignition System Circuit
- 370 Starter Motor Removal
- 370 Starter Motor Installation
- 371 Torque -
- 371 Starter Solenoid Inspection
- 371 Starter Motor Inspection
- 372 Starter Motor Disassembly
- 374 Starter Motor Assembly
- 375 Starter Motor Brush Inspection
- 375 Brush Spring Inspection
- 375 Armature Inspection
- 377 Yoke Assembly Inspection
- 377 Pinion Clutch Inspection
- 377 Starter Circuit Relay Inspection
- 379 Electric Starter Circuit
- 380 Headlight Beam Adjustment
- 380 Headlight Bulb Replacement
- 383 Tail/Brake Light Replacement
- 384 Light Switch Bulb Replacement
- 384 Indicator Light Bulb Replacement
- 385 Lighting System Circuit
- 386 Brake Light Switch Inspection
- 386 Oil Temperature Sensor Inspection (KAF400-A/C)
- 386 Oil Temperature Warning Indicator Control Unit Inspection (KAF40
- 386 Special Tool -
- 387 Oil Temperature Warning Control System Circuit
- 388 Switch Inspection
- 388 Neutral Switch Connections
- 388 Reverse Light Switch Connections (Europe Model)
- 388 Horn Switch Connections (Europe Model)
- 389 Fuse Removal
- 389 Fuse Installation
- 389 Fuse Inspection
- 391 Appendix
- 392 NOTE
- 392 Engine Doesn't Start, Starting Difficulty:
- 392 Starter motor not rotating:
- 392 Starter motor rotating but engine doesn't turn over:
- 392 Engine won't turn over:
- 392 No fuel flow:
- 392 Engine flooded:
- 392 No spark; spark weak:
- 392 Compression Low:
- 392 Poor Running at Low Speed:
- 392 Spark weak:
- 392 Fuel/air mixture incorrect:
- 392 Compression low:
- 392 Other:
- 392 Poor Running or No Power at High Speed:
- 392 Firing incorrect:
- 392 Fuel/air mixture incorrect:
- 393 Compression low:
- 393 Knocking:
- 393 Miscellaneous:
- 393 Overheating:
- 393 Firing incorrect:
- 393 Fuel/air mixture incorrect:
- 393 Compression high:
- 393 Engine load faulty:
- 393 Converter and/or belt excessive heating:
- 393 Lubrication inadequate:
- 393 Front final gear case overheating (KAF400-A/C):
- 393 Cooling system component incorrect:
- 393 Converter Operation Faulty:
- 393 Belt slipping:
- 393 Converter engagement speed too low:
- 393 Converter engagement speed too high:
- 393 Shifting too quickly:
- 393 Shifting too slowly:
- 393 Gear Shifting Faulty:
- 393 Doesn't go into gear:
- 393 Jumps out of gear:
- 394 Overshifts:
- 394 Abnormal Engine Noise:
- 394 Knocking:
- 394 Piston slap:
- 394 Valve noise:
- 394 Other noise:
- 394 Abnormal Drive Train Noise:
- 394 Converter noise:
- 394 Transmission noise:
- 394 Final drive noise:
- 394 Abnormal Frame Noise:
- 394 Shock absorber noise:
- 394 Brake noise:
- 394 Other noise:
- 394 Exhaust Smokes Excessively:
- 394 White smoke:
- 394 Black smoke:
- 394 Brown smoke:
- 394 Handling and/or Stability Unsatisfactory:
- 394 Steering wheel hard to turn:
- 394 Noise when turning (KAF400-A/C):
- 394 Steering wheel shakes or excessively vibrates:
- 395 Steering wheel pulls to one side:
- 395 Shock absorption unsatisfactory:
- 395 Brake Doesn't Hold
- 395 Battery Discharged:
- 395 Battery Overcharged: