Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
2005 Kawasaki Mule 3010 Trans 4×4 Kaf620 Service Manual – PDF DOWNLOAD
Original price was: $29.95.$16.95Current price is: $16.95.
2005 Kawasaki Mule 3010 Trans 4×4 Kaf620 Service Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
2005 Kawasaki Mule 3010 Trans 4×4 Kaf620 Service Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:409
DOWNLOADABLE:YES
FILE TYPE:PDF
2005 KAWASAKI MULE 3010 TRANS 4X4 KAF620 SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2005 Kawasaki Mule 3010 Trans 4×4 Kaf620 Service Manual
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 servicemanual. 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 ofmaintenance and repair with dates and any new parts installed.
How to Use This Manual:
In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the 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.
TABLE OF CONTENTS:
2005 Kawasaki Mule 3010 Trans 4×4 Kaf620 Service Manual
tables.............................................................................. 1 LIST OF ABBREVIATIONS........................................................... 4 Units of Mass:.................................................................. 18 Units of Volume:................................................................ 18 Units of Force:................................................................. 18 Units of Length:................................................................ 18 Units of Torque:................................................................ 18 Units of Pressure:.............................................................. 18 Units of Speed:................................................................. 18 Units of Power:................................................................. 18 Basic Torque for General Fasteners of Engine Parts.............................. 25 Basic Torque for General Fasteners of Frame Parts............................... 25 Throttle Pedal Free Play........................................................ 29 Idle Speed...................................................................... 30 Water and Coolant Mixture Ratio (Recommended)................................... 35 Belt Width...................................................................... 36 Wear Shoe Width................................................................. 37 Valve Clearance (when cold)..................................................... 39 Engine Oil...................................................................... 40 Transmission Oil................................................................ 42 Tire Tread Depth................................................................ 43 Standard Tire................................................................... 43 Front Final Gear Case Oil....................................................... 43 Brake Pedal Free Play........................................................... 45 Brake Drum Inside Diameter...................................................... 48 Brake Shoe Lining Thickness..................................................... 48 Parking Brake Lever Travel...................................................... 51 Steering Wheel Free Play........................................................ 52 Brake Light Switch Timing....................................................... 53 Spark Plug Gap.................................................................. 53 Throttle Link Lever Bolt/Shim Clearance......................................... 69 Shims........................................................................... 69 Choke Cable Free Play........................................................... 70 Valve Closing Temperature (for reference)....................................... 77 Water Pump Shaft Diameter....................................................... 94 Water Pump Shaft Bearing Inside Diameter........................................ 94 Radiator Cap Relief Pressure ................................................... 97 Thermostat Valve Opening Temperature............................................ 99 Cylinder Compression............................................................108 Cylinder Head Warp..............................................................112 Valve Seating Surface Outside Diameter..........................................113 Valve Seating Surface Width.....................................................113 Valve Spring Free Length........................................................117 Valve Head Thickness............................................................117 Valve Stem Bend.................................................................117 Valve Stem Diameter.............................................................117 Valve Guide Inside Diameter ....................................................118 Valve/Guide Clearance (Wobble Method)...........................................118 Rocker Shaft Diameter...........................................................118 Rocker Arm Inside Diameter......................................................119 Rocker Arm Push Rod Runout......................................................119 Belt Deflection.................................................................135 Spacers.........................................................................135 Spider Wear Guide Clearance.....................................................138 Cover Bushing Inside Diameter [A]...............................................139 Sheave Bushing Inside Diameter [B]..............................................139 Spider Wear Guide Thickness [B].................................................139 Spring Free Length [A]..........................................................140 Sheave Bushing Inside Diameter..................................................143 Spring Free Length [A]..........................................................144 Inner Rotor/Outer Rotor Clearance...............................................155 Inner Rotor Shaft Diameter [A]..................................................155 Outer Rotor Diameter [B]........................................................155 Outer Rotor Width [C]...........................................................155 Inner Rotor Shaft Bearing Inside Diameter [A]...................................156 Outer Rotor Housing Inside Diameter [B].........................................156 Rotor Housing Depth [C].........................................................156 Cam Height (Inlet)..............................................................172 Cam Height (Exhaust)............................................................172 Camshaft Journal Diameter.......................................................173 Camshaft Bearing Inside Diameter................................................173 Piston Ring/Groove Clearance (Top, Second)......................................177 Piston Ring End Gap (Top, Second)...............................................177 Cylinder Inside Diameter........................................................177 Piston Diameter.................................................................177 Oversize Piston and Rings.......................................................178 Connecting Rod Bend.............................................................179 Connecting Rod Twist............................................................180 Connecting Rod Big End Side Clearance ..........................................180 Connecting Rod Big End Bearing/Crankpin Clearance...............................181 Crankpin Diameter...............................................................181 Connecting Rod Big End Inside Diameter..........................................181 Crankshaft Runout ..............................................................181 Crankshaft Main Journal Diameter................................................182 Crankshaft Main Bearing Inside Diameter.........................................182 Shift Arm Pin Diameter [A]......................................................203 Shifter Block Inside Diameter [B]...............................................203 Shifter Block Outside Diameter [C]..............................................203 Shifter Groove Width [D]........................................................203 Drive Chain 20-Link Length [B]..................................................203 Shifter Block Outside Diameter [A]..............................................206 Shifter Groove Width [B]........................................................206 Shifter Block Outside Diameter..................................................209 Shifter Groove Width............................................................209 Shift Arm Pin Diameter [A]......................................................211 Shifter Groove Width [B]........................................................211 Toe-in of Front Wheels..........................................................221 Maximum Tire Air Pressure (to seat beads when cold).............................225 Tire Air Pressure (when cold)...................................................226 LSD Clutch Torque...............................................................238 Outside Friction Plate Thickness................................................239 Inside Friction Plate Thickness.................................................239 Using Spring Scale..............................................................243 Using Torque Wrench.............................................................243 Bevel Gear Backlash.............................................................244 Bevel Gear Backlash.............................................................250 Recommended Brake Fluid.........................................................272 Drum Press-fitting Force (Torque)...............................................277 Spring Action...................................................................292 Tie- rod Length (distance between boot end and locknut).........................307 Kawasaki-recommended chargers...................................................349 Battery Terminal Voltage........................................................351 Terminal Voltage: 11.5 ∼ less than 12.5 V.......................................351 Terminal Voltage: less than 11.5 V..............................................351 Regulator/Rectifier Output Voltage .............................................355 Stator Coil Resistance .........................................................356 Ignition Coil Winding Resistance ...............................................360 Ignition Coil Primary Peak Voltage..............................................361 Pickup Coil Resistance..........................................................361 Connections.....................................................................362 Pickup Coil Peak Voltage........................................................362 Carbon Brush Length.............................................................368 Commutator Diameter.............................................................369 Testing Switch..................................................................369 Testing Relay...................................................................370 Fuel Pump Leads ................................................................372 Fuel Pump Relay Internal Resistance (Tester Range: × 1 kΩ)......................372 Radiator Fan Motor Leads........................................................374 Radiator Fan Switch Resistance..................................................378 Coolant Temperature Warning Light Switch Resistance.............................379 toc................................................................................. 1 Read OWNER'S MANUAL before operating............................................ 4 EMISSION CONTROL INFORMATION................................................ 5 1....................................................................... 5 2....................................................................... 5 PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US Model only).............. 6 Foreword.................................................................... 7 General Information......................................................... 8 Before starting to perform an inspection service or carry out a ........ 9 Battery Ground...................................................... 9 Edges of Parts...................................................... 9 Solvent............................................................. 9 Cleaning vehicle before disassembly................................. 9 Arrangement and Cleaning of Removed Parts........................... 10 Storage of Removed Parts............................................ 10 Inspection.......................................................... 10 Replacement Parts................................................... 10 Assembly Order...................................................... 10 Tightening Sequence................................................. 11 Tightening Torque................................................... 11 Force............................................................... 11 Gasket, O-ring...................................................... 11 Liquid Gasket, Locking Agent........................................ 11 Press............................................................... 12 Ball Bearing and Needle Bearing..................................... 12 Oil Seal, Grease Seal............................................... 12 Circlips, Cotter Pins............................................... 12 Lubrication......................................................... 13 Direction of Engine Rotation........................................ 13 Electrical Wires.................................................... 13 KAF620-J1 Left Side View................................................ 14 KAF620-J1 Right Side View............................................... 14 Prefixes for Units:..................................................... 18 Units of Temperature:................................................... 18 Periodic Maintenance........................................................ 19 The scheduled maintenance must be done in accordance with this c........ 20 The following tables list the tightening torque for the major fa........ 22 Inside Circlip Pliers:.................................................. 28 Fuel System............................................................. 29 Throttle Pedal Free Play Inspection................................. 29 Throttle Pedal Free Play Adjustment................................. 29 Full Throttle Pedal Position Adjustment............................. 30 Idle Speed Inspection............................................... 30 Idle Speed Adjustment............................................... 30 Fuel System Cleanliness Inspection.................................. 30 Fuel Filter Inspection.............................................. 31 Intake Chamber Water Draining....................................... 31 External Carburetor Mechanism Cleaning.............................. 31 Fuel Hoses And Connections Inspection............................... 31 Fuel Hoses Replacement.............................................. 32 Air Cleaner Element Cleaning........................................ 32 Air Cleaner Housing Dust and/or Water Inspection.................... 33 Cooling System...................................................... 33 Radiator Cleaning............................................... 33 Radiator Hose and Connection Inspection......................... 34 Coolant Draining................................................ 34 Coolant Filling................................................. 35 Torque -.................................................... 35 Coolant Filter Inspection....................................... 36 Converter System.................................................... 36 Drive Belt Inspection........................................... 36 Converter Driven Pulley Shoe Inspection......................... 37 Air Cleaner Element Cleaning/Inspection......................... 37 Converter Dust or Water Draining................................ 38 Engine Top End...................................................... 38 Valve Clearance Inspection...................................... 38 Valve Clearance Adjustment...................................... 39 Special Tool -.............................................. 39 Torque -.................................................... 39 Spark Arrester Cleaning......................................... 40 Engine Lubrication.................................................. 40 Oil and/or Filter Change........................................ 40 Torque -.................................................... 40 Oil Filter Removal.............................................. 41 Special Tool -.............................................. 41 Oil Filter Installation......................................... 41 Transmission........................................................ 42 Transmission Oil Change......................................... 42 Torque -.................................................... 42 Wheels/Tires........................................................ 42 Wheels Nuts Tightness Inspection................................ 42 Torque -.................................................... 42 Tire Inspection................................................. 43 Final Drive......................................................... 43 Front Final Gear Case Oil Change................................ 43 Torque -.................................................... 43 Torque -.................................................... 43 Brakes.............................................................. 44 Brake Fluid Level Inspection ................................... 44 Brake Fluid Changing............................................ 45 Torque -.................................................... 45 Brake Pedal Free Play Adjustment................................ 45 Torque -.................................................... 46 Brake Master Cylinder Cup and Dust Seal Replacement............. 46 Special Tool -.............................................. 46 Torque -.................................................... 46 Brake Hose and Pipe Inspection.................................. 47 Brake Hose and Pipe Replacement................................. 47 Torque -.................................................... 47 Brake Wear Inspection........................................... 48 Brake Wheel Cylinder Assembly Replacement....................... 49 Torque -.................................................... 50 Parking Brake Lever Travel Adjustment .......................... 51 Steering............................................................ 52 Steering Wheel Free Play Inspection............................. 52 Steering Joint Dust Boot Inspection............................. 52 Frame............................................................... 52 Seat Belt Inspection............................................ 52 Electrical System................................................... 53 Brake Light Switch Adjustment................................... 53 Spark Plug Cleaning/Inspection.................................. 53 Spark Plug Gap Inspection....................................... 53 General Lubrication................................................. 53 Pivots and Points: Lubricate with Grease........................ 54 Cables: Lubricate with Rust Inhibitor........................... 54 Cables: Lubricate with Motor Oil................................ 54 Bolts, Nuts, and Fasteners.......................................... 55 Tightness Inspection............................................ 55 Nut, Bolt, and Fasteners to be checked...................... 55 Fuel System................................................................. 57 Throttle Pedal Free Play Inspection..................................... 63 Throttle Pedal Free Play Adjustment................................. 63 Full Throttle Pedal Position Adjustment............................. 63 Throttle Cable Installation......................................... 63 Throttle Cable Lubrication.......................................... 63 Throttle Cable Inspection........................................... 63 Control Panel Assembly Removal.......................................... 64 Control Panel Assembly Installation................................. 64 Governor Arm and Throttle Link Removal ............................. 67 Governor Arm Installation........................................... 67 Torque -........................................................ 67 Governor Assembly Removal........................................... 68 Governor Assembly Installation...................................... 68 Governor Assembly Inspection........................................ 68 Throttle Link Lever Installation.................................... 69 Torque -........................................................ 69 Maximum Engine Speed Inspection..................................... 69 Choke Cable Free Play Inspection........................................ 70 Choke Cable Free Play Adjustment.................................... 70 Choke Cable Installation............................................ 70 Choke Cable Lubrication............................................. 70 Choke Cable Inspection.............................................. 71 Idle Speed Inspection................................................... 72 Idle Speed Adjustment............................................... 72 Fuel System Cleanliness Inspection.................................. 72 Carburetor Removal.................................................. 72 Carburetor Installation............................................. 73 Torque -........................................................ 73 Torque -........................................................ 74 Sealant -....................................................... 74 Torque -........................................................ 74 Carburetor Disassembly.............................................. 74 Carburetor Assembly................................................. 75 Torque -........................................................ 75 Carburetor Cleaning................................................. 76 Carburetor Inspection............................................... 76 Coolant Filter Cleaning............................................. 77 Coolant Valve Inspection............................................ 77 Air Cleaner Element Cleaning............................................ 78 Air Cleaner Housing Removal......................................... 78 Air Cleaner Housing Installation.................................... 78 Torque -........................................................ 78 Sealant -....................................................... 78 Torque -........................................................ 78 Air Cleaner Housing Dust and/or Water Inspection.................... 78 Fuel Pump and Fuel Filter Removal....................................... 79 Fuel Pump Installation.............................................. 79 Fuel Filter Installation............................................ 79 Fuel Filter Inspection.............................................. 79 Fuel Tank Removal....................................................... 80 Fuel Tank Installation.............................................. 81 Fuel Tank Cleaning/Inspection....................................... 81 Cooling System.............................................................. 83 Kawasaki Bond (Silicone Sealant):....................................... 87 Coolant Level Inspection................................................ 91 Coolant Draining.................................................... 91 Coolant Filling..................................................... 91 Pressure Testing.................................................... 91 Water Pump Removal...................................................... 92 Water Pump Installation............................................. 93 Torque -........................................................ 93 Water Pump Inspection............................................... 94 Radiator Removal........................................................ 95 Radiator Inspection................................................. 96 Radiator Cleaning................................................... 96 The radiator cap at the reservoir tank has the pressure relief v........ 97 Radiator Cap Inspection............................................. 97 Thermostat Removal...................................................... 98 Thermostat Installation............................................. 98 Thermostat Inspection............................................... 98 Hose and Pipe Installation..............................................100 Hose Inspection.....................................................100 Radiator Fan Switch, Coolant Temperature Warning Light Switch Re........101 Radiator Fan Switch, Coolant Temperature Warning Light Switch In....101 Sealant -.......................................................101 Torque -........................................................101 Radiator Fan Switch, Coolant Temperature Warning Light Switch In....101 Engine Top End..............................................................103 Outside Circlip Pliers:.................................................107 Cylinder Compression Measurement........................................108 Cylinder Head Removal...............................................108 Cylinder Head Installation..........................................110 Torque -........................................................111 Torque -........................................................111 Cylinder Head Disassembly and Assembly (Valve Mechanism Removal ....111 Special Tool -..................................................111 Cylinder Head Warp..................................................112 Valve Clearance Inspection..............................................113 Valve Clearance Adjustment..........................................113 Valve Seat Inspection...............................................113 Valve Seat Repair...................................................113 Special Tools -.................................................113 Special Tools -.............................................114 Valve Spring Free Length............................................117 Valve Head Thickness................................................117 Valve Stem Bend.....................................................117 Valve Stem Diameter.................................................117 Valve Guide Inside Diameter.........................................118 Measuring Valve/Guide Clearance (Wobble Method).....................118 Rocker Arm/Shaft Wear...............................................118 Rocker Arm Push Rod Inspection......................................119 Exhaust Pipe Removal....................................................120 Muffler Removal.....................................................120 Exhaust Pipe and Muffler Installation...............................120 Exhaust Pipe and Muffler Inspection.................................121 Spark Arrester Cleaning.............................................121 Converter System............................................................123 Outside Circlip Pliers:.................................................129 Air Cleaner Housing Removal.............................................130 Air Cleaner Element Removal.........................................130 Air Cleaner Element Cleaning/Inspection.............................130 Torque Converter Removal................................................131 Special Tool -......................................................131 Torque Converter Installation.......................................132 Torque -........................................................132 Torque -........................................................133 Torque Converter Case Removal.......................................133 Drive Belt Removal......................................................134 Drive Belt Installation.............................................134 Drive Belt Deflection Inspection....................................135 Drive Belt Deflection Adjustment....................................135 Torque -........................................................135 Drive Belt Inspection...............................................135 Drive Pulley Disassembly................................................136 Special Tool -......................................................136 Special Tool -......................................................136 Drive Pulley Assembly...............................................137 Torque -........................................................137 Special Tool -..................................................138 Torque -........................................................138 Torque -........................................................138 Spider/Wear Guide Clearance Adjustment..............................138 Drive Pulley Inspection.............................................138 Bushing Installation................................................140 Driven Pulley Disassembly...............................................141 Special Tools -.....................................................141 Special Tool -......................................................141 Driven Pulley Assembly..............................................142 Torque -........................................................142 Special Tools -.................................................142 Special Tool -..................................................143 Driven Pulley Inspection............................................143 Bushing Installation................................................144 Engine Lubrication System...................................................145 Oil Filter Wrench:......................................................149 WARNING.................................................................151 Oil Level Inspection................................................151 Oil and/or Filter Change............................................153 Oil Filter Removal..................................................153 Oil Filter Installation.............................................153 Oil Pump and Relief Valve Removal.......................................154 Oil Pump and Relief Valve Installation..............................154 Oil Pump and Relief Valve Inspection................................154 Oil Screen Removal......................................................157 Oil Screen Installation.............................................157 Oil Screen Cleaning/Inspection......................................157 Oil Pressure Switch Removal.............................................158 Oil Pressure Switch Installation....................................158 Sealant -.......................................................158 Torque -........................................................158 Engine Removal/Installation.................................................159 Engine Removal..........................................................162 Engine Installation.................................................163 Torque -........................................................163 Engine Bottom End...........................................................165 Piston Pin Puller Assembly:.............................................170 Crankcase Cover Removal.................................................171 Crankcase Cover Installation........................................171 Torque -........................................................171 Camshaft Removal........................................................172 Camshaft Installation...............................................172 Camshaft Inspection.................................................172 Cam Wear............................................................172 Camshaft Bearing/Journal Wear.......................................173 Piston Removal .........................................................174 Special Tool -......................................................174 Piston Installation.................................................175 Special Tools -.................................................176 Torque -........................................................176 Piston Ring, Piston Ring Groove Wear................................177 Piston Ring End Gap.................................................177 Cylinder Inside Diameter............................................177 Piston Diameter.....................................................177 Boring, Honing......................................................178 Connecting Rod Removal..................................................179 Connecting Rod Installation.........................................179 Crankshaft Removal..................................................179 Crankshaft Installation.............................................179 Crankshaft Cleaning.................................................179 Connecting Rod Bend/Twist...........................................179 Connecting Rod Big End Side Clearance...............................180 Connecting Rod Big End Bearing/Crankpin Wear........................180 Torque -........................................................180 Torque -........................................................181 Crankshaft Runout...................................................181 Crankshaft Main Bearing/Journal Wear................................182 Breather Valve Removal..................................................183 Breather Valve Installation.........................................183 Breather Valve Inspection...........................................183 Transmission................................................................185 Outside Circlip Pliers:.................................................193 CAUTION.................................................................194 Transmission Oil Level Inspection...................................194 Transmission Oil Change.............................................194 Transmission Case Removal...............................................195 Transmission Case Installation .....................................195 Torque -........................................................195 Transmission Case Splitting.........................................196 Transmission Case Assembly..........................................196 Sealant -.......................................................196 Torque -........................................................196 Transmission and Hi/Low Shift Cables Installation.......................197 Shift Lever Position Inspection.....................................200 Shift Lever Position Adjustment.....................................200 Transmission Shift Cable Inspection.................................201 Transmission Removal ...............................................201 Special Tool -..................................................201 Special Tool -..................................................202 Transmission Installation...........................................202 Torque -........................................................202 Transmission and Shift Mechanism Inspection.........................203 Hi/Low Shift Cable Installation.........................................204 Hi/Low Shift Cable Inspection.......................................204 Hi/Low Gear and Shift Mechanism Removal ............................204 Special Tool -..................................................205 Hi/Low Gear and Shift Mechanism Installation .......................205 Torque -........................................................206 Hi/Low Gear and Shift Mechanism Inspection .........................206 2WD/4WD Shift Cable Adjustment..........................................207 2WD/4WD Shift Cable Lubrication.....................................208 2WD/4WD Shift Cable Inspection......................................208 2WD/4WD Shift Mechanism Removal ....................................208 Special Tool -..................................................209 2WD/4WD Shift Mechanism Installation................................209 Torque -........................................................209 2WD/4WD Shift Mechanism Inspection..................................209 Differential Shift Cable Adjustment.....................................210 Differential Shift Cable Lubrication................................210 Differential Shift Cable Inspection.................................210 Differential Shift Mechanism Removal................................210 Differential Shift Mechanism Installation...........................211 Torque -........................................................211 Differential Shift Mechanism Inspection.............................211 Differential Gear Removal...........................................211 Differential Gear Installation......................................212 Torque -........................................................212 Differential Gear Inspection........................................212 Bearing Replacement.....................................................213 Special Tools -.....................................................213 Special Tool -......................................................213 Torque -............................................................213 Special Tool -......................................................213 Ball Bearing Inspection.............................................213 Needle Bearing Inspection...........................................213 Oil Seal Inspection.................................................213 Wheels/Tires................................................................217 Toe-in is the amount that the front wheels are closer together i........221 Toe-in Adjustment...................................................221 Torque -........................................................222 Wheel Removal...........................................................223 Wheel Installation..................................................223 Torque -........................................................223 Wheel (Rim) Inspection..............................................223 Wheel (Rim) Replacement.............................................223 Tire Removal ...........................................................225 Tire Installation ..................................................225 Tire Inspection.....................................................226 Final Drive.................................................................227 Bearing Puller:.........................................................233 Front Final Gear Case Oil Level Inspection .............................234 Torque -............................................................234 Front Final Gear Case Oil Change....................................234 Front Final Gear Case Removal.......................................235 Front Final Gear Case Installation..................................235 Torque -........................................................235 Front Final Gear Case Disassembly...................................236 Front Final Gear Case Assembly......................................236 Torque -........................................................237 Differential Unit and Ring Gear Disassembly.........................237 Differential Unit and Ring Gear Assembly............................237 Torque -........................................................238 LSD Clutch Torque Inspection........................................238 LSD Clutch Plate Inspection.........................................239 Pinion Gear Unit Disassembly........................................239 Special Tools -.................................................239 Special Tool -..................................................239 Pinion Gear Unit Assembly...........................................239 Torque -........................................................240 Front Final Bevel Gear Adjustment...................................240 Special Tool -..................................................243 Special Tool -......................................................243 Special Tool -..................................................244 Special Tool -..................................................244 Bevel Gear Inspection...............................................246 Differential Gear Inspection........................................246 Tapered Roller Bearing Inspection...................................246 Ball Bearing Inspection.............................................246 Oil Seal Inspection.................................................246 Bevel Gear Case Removal.................................................247 Bevel Gear Case Installation........................................247 Torque -........................................................247 Bevel Gear Case Disassembly.........................................247 Special Tools -.................................................247 Special Tools -.................................................248 Special Tool -..................................................248 Special Tool -..................................................248 Special Tools -.................................................248 Bevel Gear Case Assembly............................................248 Torque -........................................................248 Drive Bevel Gear Removal............................................249 Special Tool -..................................................249 Drive Bevel Gear Installation.......................................249 Torque -........................................................249 Bevel Gear Adjustment ..............................................249 Special Tool -..................................................250 Bevel Gear Inspection...............................................253 Ball Bearing Inspection.............................................253 Oil Seal Inspection.................................................253 Damper Inspection...................................................253 Propeller Shaft Removal.................................................254 Propeller Shaft Installation........................................255 Propeller Shaft Inspection..........................................256 Front Axle Removal .....................................................257 Front Axle Installation ............................................257 Torque -........................................................257 Rear Drive Shaft and Axle Removal...................................257 Rear Drive Shaft and Axle Installation..............................258 Drive Shaft and Axle Inspection.....................................258 Dust Boot Inspection................................................259 Front Axle Joint Boot Replacement...................................259 Special Tool -..................................................259 Special Tool -..................................................260 Special Tool -..................................................262 Ball Bearing Inspection.............................................263 Grease Seal Inspection..............................................264 Brakes......................................................................265 Inside Circlip Pliers:..................................................271 Brake Fluid Recommendation..............................................272 Brake Fluid Level Inspection........................................272 Brake Fluid Changing................................................272 Brake Line Air Bleeding ........................................273 Torque -....................................................273 Brake Pedal Free Play Adjustment........................................274 Master Cylinder Removal.............................................274 Master Cylinder Installation........................................274 Torque -........................................................274 Master Cylinder Disassembly.........................................274 Master Cylinder Assembly............................................274 Master Cylinder Inspection .........................................275 Brake Hose and Pipe Inspection..........................................276 Brake Hose and Pipe Replacement.....................................276 Brake Drum Removal......................................................277 Special Tools -.....................................................277 Brake Drum Installation.............................................277 Special Tools -.................................................277 Torque -........................................................278 Brake Drum Wear.....................................................278 Brake Panel Removal.....................................................279 Brake Panel Installation............................................280 Torque -........................................................281 Wheel Cylinder Assembly.............................................282 Wheel Cylinder Inspection...........................................282 Brake Shoe Lining Wear..............................................282 Brake Shoe Spring Inspection........................................283 Parking Brake Lever Travel Adjustment ..................................284 Parking Brake Cable Lubrication.....................................284 Parking Brake Cable Inspection......................................284 Suspension..................................................................285 Steering Stem Nut Wrench:...............................................289 Strut (Front Shock Absorber) Removal....................................290 Strut (Front Shock Absorber) Installation...........................290 Torque -........................................................290 Strut Spring Replacement............................................291 Torque -........................................................292 Rear Shock Absorber Preload Adjustment..............................292 Special Tool -..................................................292 Rear Shock Absorber Removal.........................................293 Rear Shock Absorber Installation....................................293 Torque -........................................................293 Shock Absorber Inspection...........................................293 Front Suspension Arm Removal............................................294 Front Suspension Arm Installation...................................294 Torque -........................................................294 Front Suspension Arm Inspection.....................................295 Leaf Spring Removal.....................................................296 Leaf Spring Installation............................................296 Torque -........................................................296 Torque -........................................................296 Leaf Spring Inspection..............................................297 Steering....................................................................299 Steering Wheel Position Adjustment......................................303 Steering Wheel Free Play Inspection.................................303 Steering Wheel Centering............................................303 Torque -........................................................303 Steering Wheel and Steering Shaft Removal...........................303 Steering Wheel and Main Shaft Installation..........................304 Torque -........................................................304 Steering Gear Assembly Removal..........................................305 Steering Gear Assembly Installation.................................305 Torque -........................................................306 Steering Gear Preload Adjustment....................................306 Torque -........................................................306 Tie-rod Length Adjustment...........................................307 Torque -........................................................307 Steering Joint Dust Boot Inspection.................................307 Steering Knuckle Removal................................................308 Steering Knuckle Installation.......................................308 Torque -........................................................308 Frame.......................................................................311 Front Seat Removal......................................................318 Front Seat Installation.............................................318 Rear Seat Removal...................................................319 Rear Seat Installation..............................................320 Seat Belt Removal...................................................320 Seat Belt Installation..............................................321 Torque -........................................................321 Torque -........................................................321 Control Panel Removal...................................................322 Glove Compartment Removal...........................................322 Front Cargo Hood Removal................................................323 Front Cargo Compartment Removal.....................................323 Cargo Bed Removal.......................................................324 Cargo Bed Installation..............................................325 Front Bar Removal.......................................................326 Front Bar Installation..............................................326 Torque -........................................................326 Rear Bar Removal....................................................326 Rear Bar Installation...............................................327 Torque -........................................................327 Center Bar Removal..................................................327 Center Bar Installation.............................................327 Torque -........................................................327 Cargo Bed Latch Position Inspection.................................328 Cargo Bed Latch Position Adjustment.................................328 Front Cover Removal.....................................................329 Front Fender Removal................................................330 Radiator Side Cover Removal.........................................330 Radiator Side Cover Installation....................................331 Radiator Side Cover Flap Removal....................................331 Floor Center Panel Removal..........................................331 Rear End Sub-frame Removal..............................................333 Rear End Sub-frame Installation ....................................333 Torque -........................................................333 Electrical System...........................................................335 Crankcase Splitting Tool Assembly:......................................341 Horn [A]................................................................342 There are a number of important precautions that are musts when ........345 Battery Removal.........................................................347 Battery Installation................................................347 Torque -........................................................348 Battery Activation..................................................348 Precautions.........................................................350 1)..............................................................350 2)..............................................................350 3)..............................................................350 4)..............................................................350 Interchange.........................................................350 Charging Condition Inspection...................................351 Refreshing Charge ..............................................351 Alternator Rotor and Stator Removal.....................................353 Special Tool -......................................................353 Alternator Rotor and Stator Installation............................354 Torque -........................................................354 Charging System Operational Inspection..............................355 Stator Coil Resistance..............................................356 Regulator/Rectifier Inspection......................................356 Charging System Circuit.............................................358 WARNING.................................................................359 Spark Plug Removal/Installation.....................................359 Torque -........................................................359 Spark Plug Gap Inspection...........................................359 Spark Plug Cleaning/Inspection......................................359 Ignition Coil Removal...............................................359 Ignition Coil Installation..........................................360 Ignition Coil Inspection............................................360 Ignition Coil Primary Peak Voltage Inspection.......................360 Special Tools -.................................................360 Pickup Coil Removal.................................................361 Pickup Coil Inspection..............................................361 Pickup Coil Peak Voltage Inspection.................................362 Special Tool -..................................................362 Ignition System Inspection..........................................363 Ignition System Circuit.............................................364 Starter Motor Removal...................................................365 Starter Motor Installation..........................................365 Torque -........................................................365 Starter Motor Disassembly...........................................365 Starter Motor Assembly..............................................367 Carbon Brush Inspection.............................................368 Yoke Inspection.....................................................368 Brush Plate Inspection..............................................368 Commutator Cleaning/Inspection......................................368 Armature Inspection.................................................369 Pinion Gear Inspection..............................................369 Starter Switch Inspection...........................................369 Starter Circuit Relay Inspection....................................370 Electric Starter Circuit............................................371 The fuel pump does not operate when the ignition switch is turne........372 Fuel Pump Operational Inspection....................................372 Fuel Pump Relay Internal Resistance.................................372 Fuel Pump and Relay Circuit.........................................373 Radiator Fan Circuit Inspection ........................................374 Radiator Fan Motor Inspection.......................................374 Radiator Fan Circuit................................................374 Headlight Beam Adjustment...............................................375 Headlight Bulb Replacement..........................................375 Tail/Brake Light Replacement........................................376 Lighting System Circuit.............................................377 Brake Light Switch Adjustment...........................................378 Switch Inspection...................................................378 Radiator Fan Switch Inspection......................................378 Coolant Temperature Warning Light Switch Inspection.................379 Fuse Removal............................................................380 Fuse Installation...................................................380 Fuse Inspection.....................................................380 Wiring Inspection.......................................................381 Appendix....................................................................385 NOTE....................................................................386 Engine Doesn't Start, Starting Difficulty:..........................386 Starter motor not rotating:.....................................386 Starter motor rotating but engine doesn't turn over:............386 Engine won't turn over:.........................................386 No fuel flow:...................................................386 Engine flooded:.................................................386 No spark; spark weak:...........................................386 Compression Low:................................................386 Poor Running at Low Speed:..........................................386 Spark weak:.....................................................386 Fuel/air mixture incorrect:.....................................386 Compression low:................................................386 Other:..........................................................386 Poor Running or No Power at High Speed:.............................387 Firing incorrect:...............................................387 Fuel/air mixture incorrect:.....................................387 Compression low:................................................387 Knocking:.......................................................387 Miscellaneous:..................................................387 Overheating:........................................................387 Firing incorrect:...............................................387 Fuel/air mixture incorrect:.....................................387 Compression high:...............................................387 Engine load faulty:.............................................387 Converter and/or belt excessive heating:........................387 Lubrication inadequate:.........................................387 Front final gear case overheating:..............................387 Coolant incorrect:..............................................387 Cooling system component incorrect:.............................387 Over Cooling........................................................387 Converter Operation Faulty:.........................................387 Belt slipping:..................................................387 Converter engagement speed too low:.............................387 Converter engagement speed too high:............................387 Shifting too quickly:...........................................388 Shifting too slowly:............................................388 Gear Shifting Faulty:...............................................388 Doesn't go into gear:...........................................388 Jumps out of gear:..............................................388 Overshifts:.....................................................388 Abnormal Engine Noise:..............................................388 Knocking:.......................................................388 Piston slap:....................................................388 Valve noise:....................................................388 Other noise:....................................................388 Abnormal Drive Train Noise:.........................................388 Converter noise:................................................388 Transmission noise:.............................................388 Final drive noise:..............................................388 Abnormal Frame Noise:...............................................388 Shock absorber noise:...........................................388 Brake noise:....................................................388 Other noise:....................................................388 Exhaust Smokes Excessively:.........................................388 White smoke:....................................................388 Black smoke:....................................................388 Brown smoke:....................................................389 Handling and/or Stability Unsatisfactory:...........................389 Steering wheel hard to turn:....................................389 Noise when turning:.............................................389 Steering wheel shakes or excessively vibrates:..................389 Steering wheel pulls to one side:...............................389 Shock absorption unsatisfactory:................................389 Brake Doesn't Hold..................................................389 Battery Discharged:.................................................389 Battery Overcharged:................................................389
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
1 review for 2005 Kawasaki Mule 3010 Trans 4×4 Kaf620 Service Manual – PDF DOWNLOAD
Add a review
Axl Daxton –
Document has the information I was looking for