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• Free 2016 Kawasaki Mule 610 Service Manual
• 2016 Kawasaki Mule 610 Service Manual

Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of the crankcase. 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 atmosphere.

Also, vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. When the vehicle is used at high altitude, the thinner atmosphere makes the air/fuel mixture richer reducing performance and increasing fuel usage. To improve the performance of vehicles operated at high altitude, optional replacement of certain carburetor components are available. Have the carburetor adjusted by your authorized Kawasaki dealer if you intend to use this vehicle above 500 m (1 600 feet).

However the carburetor must be returned to original settings before using at lower altitudes.

. MULE 610 4×4 MULE 600 Utility Vehicle Service Manual. Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Converter System Engine Lubrication System Engine Removal/Installation Engine Bottom End Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2004 Kawasaki Heavy Industries. Ltd., First Edition (1): Oct.

10, 2004 (M). LIST OF ABBREVIATIONS ampere(s) pounds(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current. 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. 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. venient operation.

Use proper tools and genuine Kawasaki vehi-. cle parts. Special tools, gauges, and testers Indicates a procedural step or work to be that are necessary when servicing Kawasaki done. GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.Model Identification.

Model Identification. General Specifications.Unit Conversion Table.1-12. 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper- ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.

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.

1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.

1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. GENERAL INFORMATION 1-7 Model Identification KAF400-A1 Left Side View KAF400-A1 Right Side View The KAF400-C1 is identical to the KAF400-A1 in every aspect: controls, features, and specifications except the camouflage surface treatment and weight. 1-8 GENERAL INFORMATION Model Identification KAF400-B1 Left Side View KAF400-B1 Right Side View. GENERAL INFORMATION 1-9 General Specifications Items KAF400-A1/B1/C1 Dimensions Overall Length 2 720 mm (107.09 in.) Overall Width 1 335 mm (52.56 in.) Overall Height (A, C) 1 802 mm (70.94 in.), (B) 1 781 mm (70.12 in.) Wheelbase 1 779 mm (70.04 in.) Tread: Front 1 051 mm (41.38 in.).

1-10 GENERAL INFORMATION General Specifications Items KAF400-A1/B1/C1 Drive Train Primary Reduction System: Type Belt drive torque converter 3.653 ∼ 0.794 Reduction ratio Transmission Gear Ratio: Forward: High 2.916 (35/24 × 36/18) (A, C) 4.315 (41/19 × 36/18), (B) – Reverse: 3.750 (30/16 ×. GENERAL INFORMATION 1-11 General Specifications Items KAF400-A1/B1/C1 Brake Type: Front and Rear Drum (Hydraulic) Parking brake type Drum (Mechanical internal expansion) Electrical Equipment Battery 12 V 14 Ah Headlight: Type Semi-sealed beam Bulb 12 V 35 W × 2 Tail/Brake Light 12 V 5/21 W Reverse Light (EUR) 12 V 10 W. 1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque milli × 0.001 micro µ. PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart.Wheels/Tires.2-23 Torque and Locking Agent.Wheels Nuts Tightness Specifications.Inspection.2-23 Special Tools.2-11 Tire Wear Inspection.2-23 Periodic Maintenance Procedures.2-12 Final Drive (KAF400-A/C models). 2-23 Fuel System. 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.

First FREQUENCY Whichever Regular Service Service comes first After 50 h. PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY First Whichever Regular Service Service comes first After 50 h, Every Every or 1 000 250 h, or 500 h, or Page km of use 5 000 km 10 000 of use km of use OPERATION Every Front final gear case oil and transmission oil. 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). PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Driven Pulley Bolt Deflection Bolts 0.92 80 inlb Driven Shoe Screws 0.11 9.7 inlb Converter Cover Bolts 0.45 39 inlb Converter Case Front Bolts (26.5 mm) Converter Case Rear Bolts (25 mm) Converter Case Cover Screws 44 inlb Bracket Bolts. 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb 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. PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Rear Axle Nuts Suspension Strut Mounting Nuts Strut Clamp Nuts Suspension Arm Pivot Bolts 88.2 Front Suspension Arm Joint Nuts 78.5 Swingarm Joint Nut Swingarm Rod Bolts Rear Shock Absorber Mounting Nuts Steering Steering Wheel Mounting Nut. 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. PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System 2 ∼ 5 mm (0.08 ∼ 0.20 in.) Throttle Pedal Free Play – – – 1 100 ∼ 1 250 r/min (rpm) Idle Speed – – – Engine Top End 0.10 ∼. 2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Brakes Brake Fluid: Type DOT3 – – – Fluid Level Between upper and lower level lines – – – 2 ∼ 5 mm (0.08 ∼ 0.20 in.) Brake Pedal Play – – – 165.00 ∼. PERIODIC MAINTENANCE 2-11 Special Tools Inside Circlip Pliers: Oil Filter Wrench: 57001-143. 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).

PERIODIC MAINTENANCE 2-13 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.

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 sol- vent using a soft bristle brush. PERIODIC MAINTENANCE 2-15 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. 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 ex- plosive under certain conditions. PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures. Position the crankshaft at TDC of the end of the compres- sion stroke.

Turn the alternator rotor counterclockwise so that the pro- jection A on the plate B comes to the cylinder as shown. 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. PERIODIC MAINTENANCE 2-19 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. 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.

PERIODIC MAINTENANCE 2-21 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. 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: ○ 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. PERIODIC MAINTENANCE 2-23 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 re- torque them to the specified torque. Torque - Wheel Nuts: 34 Nm (3.5 kgfm, 25 ftlb) ○. 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 Nm (2.0 kgfm, 14 ftlb). Fill the gear case up to the bottom A of filler opening B with the oil specified below. PERIODIC MAINTENANCE 2-25 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'. 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. Pump brake pedal and hold it. Close bleed valve. PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Brake Master Cylinder Cup and Dust Seal Replacement. Remove the master cylinder (see Master Cylinder Re- moval 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. 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 main- tained. Bend and twist the rubber hose while examining Replace it if any cracks B or bulges C are noticed. PERIODIC MAINTENANCE 2-29 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 Nm (2.5 kgfm, 18 ftlb). 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. PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures.

Replace the rear wheel cylinder with a new one. Apply liquid gasket to the hatched area A. Sealant - Three Bond: 1109. Tighten: Torque - Wheel Cylinder Mounting Bolts: 12 Nm (1.2 kgfm, 106 inlb) Brake Pipe Nipple: 18 Nm (1.8 kgfm, 13 ftlb). 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 be- hind the parking brake lever. Be sure to adjust both the left and right cables evenly, and then securely tighten the adjuster mounting nuts B.

PERIODIC MAINTENANCE 2-33 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 Nm (3.5 kgfm, 25 ftlb).

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. PERIODIC MAINTENANCE 2-35 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. 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). PERIODIC MAINTENANCE 2-37 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.

FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View.Fuel System Cleanliness Specifications.Inspection.3-15 Throttle Pedal and Cable.Carburetor Removal. 3-15 Throttle Pedal Free Play Carburetor Installation.3-16 Inspection.Carburetor Disassembly.3-16 Throttle Pedal Free Play Carburetor Assembly. 3-2 FUEL SYSTEM Exploded View. FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks Nm kgfm ftlb Air Cleaner Housing Bolts Carburetor Mounting Nuts 0.70 61 inlb Choke Valve Screws 0.90 0.09 7.8 inlb Throttle Valve Screws 0.90 0.09 7.8 inlb Pilot Jet 0.70 0.07 6.1 inlb Pilot Jet Plug 0.25 22 inlb. 3-4 FUEL SYSTEM Exploded View. FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks Nm kgfm ftlb Panel Cover Bolts 0.45 39 inlb Control Panel Bolt 0.70 61 inlb Plate Connection Bolts 0.90 78 inlb Control Panel Mounting Bolts Governor Arm Nut 0.60 52 inlb Fuel Pump Mounting Bolts 0.55 48 inlb Air Cleaner Housing Bolts. 3-6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Pedal and Cable 2 ∼ 5 mm (0.08 ∼ 0.20 in.) Throttle Pedal Free Play – – – Choke Cable 0 ∼ 1 mm (0 ∼ 0.04 in.) Choke Knob Free Play –.

FUEL SYSTEM 3-7 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.

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 as- sembly shroud B with a drill bit of the 5 mm (0.02 in.) diameter. FUEL SYSTEM 3-9 Governor Link Mechanism. Turn the bushing A counterclockwise until fitting on the link with click B. Hold the carburetor throttle full open A, tighten the gov- ernor nut B with pivot arm C and governor arm D are turned fully clockwise. 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). FUEL SYSTEM 3-11 Governor Link Mechanism 1. Governor Arm 6.

Throttle Cable 3. Governor Spring 8. Governor Arm Clamp Nut 5. Control Panel.

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. 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. 3-14 FUEL SYSTEM Choke Cable Choke Cable Inspection.

With the choke cable disconnected at both ends, the ca- ble should move freely A within the cable housing. If the cable does not move freely after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable. FUEL SYSTEM 3-15 Carburetor Idle Speed Inspection. Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter.

Idle Speed Adjustment. Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Fuel System Cleanliness Inspection. 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 Nm (0.70 kgfm, 61 inlb). FUEL SYSTEM 3-17 Carburetor.

Remove: Pin A Float B and Float Valve Needle. Remove: Main Jet A. Remove: Pilot Jet Plug A.

Remove: Pilot Jet A. 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 Nm (0.09 kgfm, 7.8 inlb) Throttle Valve Screws: 0.90 Nm (0.09 kgfm, 7.8 inlb). FUEL SYSTEM 3-19 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 appli- ance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flashpoint solvents to clean the carburetor. 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. FUEL SYSTEM 3-21 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 car- buretor and engine. 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 Nm (1.7 kgfm, 12 ftlb) Fuel Pump Bracket Bolt: 5.4 Nm (0.55 kgfm, 48 inlb). FUEL SYSTEM 3-23 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF.

Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks. 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. FUEL SYSTEM 3-25 Fuel Filter Fuel Filter Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.

Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks. 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. ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View.Specifications. Special Tools. Cylinder Head.Cylinder Compression Measurement.Cylinder Head Removal.Cylinder Head Installation.Push Rod Inspection.Valve Mechanism Removal/Installation.Rocker Arm Inspection. Cylinder Head Warp. 4-2 ENGINE TOP END Exploded View.

ENGINE TOP END 4-3 Exploded View Torque Fastener Remarks Nm kgfm ftlb Cylinder Head Cover Bolts 0.70 61 inlb Cylinder Head Bolts Engine Shroud Bolts 0.60 52 inlb Valve Adjusting Nut Lock Screw 0.70 61 inlb Rocker Arm Bolts Exhaust Pipe Clamp Nuts Muffler Clamp Nuts Muffler Mounting Bolts EO: Apply engine oil. 4-4 ENGINE TOP END Specifications Item Standard Service Limit Cylinder Head 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 – – – TIR 0.5 mm (0.02 in.) Cylinder Head Warp –. ENGINE TOP END 4-5 Special Tools Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 38.5: 57001-221 Valve Seat Cutter, 45° - 32: Valve Seat Cutter Holder, 7: Valve Seat Cutter, 45° - 35: Valve Seat Cutter Holder Bar: Valve Seat Cutter, 32°. 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 be- tween the piston and the cylinder wall will help seal com- pression as it does during normal running. ENGINE TOP END 4-7 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 compres- sion stroke. Loosen: Lock Screws A.

4-8 ENGINE TOP END Cylinder Head. Tighten the cylinder head bolts following the tightening sequence as shown. Torque - Cylinder Head Bolts: 37 Nm (3.8 kgfm, 27 ftlb). Apply engine oil to the push rods A and install them onto the tappet B.

ENGINE TOP END 4-9 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. 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 sur- face. ENGINE TOP END 4-11 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.

4-12 ENGINE TOP END Valves Valve Seat Repair. Follow the manufacturer’s instructions for use of valve seat cutters.

Free 2016 Kawasaki Mule 610 Service Manual

Special Tools - Valve Seat Cutter, 45° - 35: IN Valve Seat Cutter, 32° - 38.5: IN Valve Seat Cutter, 45° - 32: EX Valve Seat Cutter, 32°. 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.

4-14 ENGINE TOP END Valves. ENGINE TOP END 4-15 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. 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 7.000 ∼ 7.015 mm (0.2756 ∼ 0.2762 in.) Standard: Service Limit: 7.08 mm (0.279 in.) Measuring Valve/Guide Clearance (Wobble Method). ENGINE TOP END 4-17 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.

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 Nm (3.2 kgfm, 23 ftlb) Muffler Clamp Nuts C: 31 Nm (3.2 kgfm, 23 ftlb) Exhaust Pipe Clamp Nuts D: 20 Nm (2.0 kgfm, 14 ftlb). CONVERTER SYSTEM 5-1 Converter System Table of Contents Exploded View.Specifications. Special Tools. Air Cleaner.Air Cleaner Element Removal. Air Cleaner Element Cleaning/Inspection.

Air Cleaner Housing Removal. Torque Converter.Torque Converter Removal.Torque Converter Installation. 5-10 Torque Converter Case Removal.

5-2 CONVERTER SYSTEM Exploded View. CONVERTER SYSTEM 5-3 Exploded View Torque Fastener Remarks Nm kgfm ftlb Drive Pulley Bolt Drive Pulley Cover Bolts Spider Weight Pin Nuts 0.70 61 inlb Driven Pulley Bolt Deflection Bolts 0.92 80 inlb Driven Wear Shoe Screws 0.11 9.7 inlb L: Apply a non-permanent locking agent.

5-4 CONVERTER SYSTEM Exploded View. CONVERTER SYSTEM 5-5 Exploded View Torque Fastener Remarks Nm kgfm ftlb Converter Cover Bolts 0.45 39 inlb Converter Case Front Bolts (26.5 mm) Converter Case Rear Bolts (25 mm) Converter Case Cover Screws 44 inlb Bracket Bolts 0.90 78 inlb Air Filter Housing Bolts G: Apply grease. 5-6 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt 22 ∼ 32 mm 22 ∼ 50 mm (0.87 ∼ 1.97 in.) Belt Deflection (0.87 ∼ 1.26 in.) 26.1 ∼ 27.3 mm Belt Width 25.2 mm (0.99 in.) (1.03 ∼ 1.07 in.) Drive Pulley 28.005 ∼. CONVERTER SYSTEM 5-7 Special Tools Outside Circlip Pliers: Drive Pulley Holder: 57001-144 Bearing Driver Set: Drive Pulley Wrench: Flywheel & Pulley Holder: Drive Pulley Holder: Drive Pulley Puller Bolt: Driven Pulley Holder: Pulley Holder Attachment:. 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. CONVERTER SYSTEM 5-9 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. Remove the two bolts A, holding the drive pulley bolt B with a wrench. 5-10 CONVERTER SYSTEM Torque Converter NOTE ○ Before removing the drive belt, observe the direction the belt’s printed information A (such as numbers, manu- facture’s name or arrow marks) is facing so that it may be reinstalled on the pulleys to rotate in the same direc- tion as originally installed. CONVERTER SYSTEM 5-11 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. 5-12 CONVERTER SYSTEM Torque Converter. Install the drive pulley holder A (see Torque Converter Removal).

Special Tool - Drive Pulley Holder:. Tighten the drive pulley bolt B, holding the drive pulley with the drive pulley holder as shown. Torque - Drive Pulley Bolt: 94 Nm (9.6 kgfm, 69 ftlb) CAUTION Do not use the impact wrench when tightening the. CONVERTER SYSTEM 5-13 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) 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.

5-14 CONVERTER SYSTEM Torque Converter Torque Converter Case Installation. Install: O-rings A Collars B. CONVERTER SYSTEM 5-15 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. 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 Mainte- nance chapter. Drive Belt Deflection Inspection. CONVERTER SYSTEM 5-17 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:.

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. CONVERTER SYSTEM 5-19 Drive Pulley If the spider shoes A are damaged, replace them. Check the spider shoe side clearance (see Spider Shoe Side Clearance Inspection).

If the ramp weights A are damaged or worn, replace them. If the pins B are damaged or worn, replace them.

If the rollers A are damaged or worn, replace the spider B. 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 0.05 ∼. CONVERTER SYSTEM 5-21 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. 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. CONVERTER SYSTEM 5-23 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:. 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. CONVERTER SYSTEM 5-25 Driven Pulley Driven Pulley Inspection If the sheave surfaces A appear damaged, replace the sheaves.

Replace any sheave which has uneven wear on the belt contacting surface. Straight Edge B If the guide bushings A are damaged or worn, replace the movable sheave. 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 bush- ing are flush with the shoulder C in the holes. Special Tool - Bearing Driver Set: Driven Pulley Assembly. CONVERTER SYSTEM 5-27 Driven Pulley. Put the circlip A on the ramp.

Install the spring holder B. Push down the ramp halfway by tightening the nut C. Turn the movable sheave A counterclockwise 120° with the driven pulley holder B. Special Tool - Driven Pulley Holder:.

ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View.Specifications. Engine Oil Flow Chart.Engine Oil and Oil Filter.Oil Level Inspection.Engine Oil Change.Oil Filter Replacement. Oil Pump, Relief Valve.Oil Pump Removal.Oil Pump Installation.

6-2 ENGINE LUBRICATION SYSTEM Exploded View. ENGINE LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks Nm kgfm ftlb Oil Line Plugs 0.40 34 inlb Oil Filter 87 inlb Oil Filter Joint 0.70 61 inlb Joint (KAF400-A/C) 0.75 65 inlb Oil Temperature Sensor (KAF400-A/C) 0.56 49 inlb Engine Oil Drain Plugs 0.70 61 inlb. 6-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Service Limit Engine Oil and Oil Filter Engine Oil: Grade API SF or SG – – – API SH or SJ with JASO MA Viscosity SAE10W-40 – – – Capacity 1.1 L (1.16 US qt) (when filter is not removed) – – – 1.3 L (1.37 US qt) (when filter is removed) –. ENGINE LUBRICATION SYSTEM 6-5 Engine Oil Flow Chart 1.

Rocker Arms 3. Oil Filter 4.

Relief Valve 6. Crankshaft 7.

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. 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. 6-8 ENGINE LUBRICATION SYSTEM Oil Pump, Relief Valve Oil Pump Removal. Remove the crankcase cover (see Crankcase Cover Re- moval in the Camshaft/Crankshaft chapter). Remove the circlip A and oil pump assembly (pump cover plate, inner rotor, outer rotor).

Oil Pump Installation. 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, re- place the crankcase cover.

Pump Housing Inside Diameter 40.680 ∼. 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. 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. 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. ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View.Special Tool.Engine Removal/Installation.Engine Removal. Engine Installation. 7-2 ENGINE REMOVAL/INSTALLATION Exploded View.

ENGINE REMOVAL/INSTALLATION 7-3 Exploded View Torque Fastener Remarks Nm kgfm ftlb Engine Mounting Bolts and Nuts 24.5 Connecting Plate Bolts (M8) Connecting Plate Bolts (M10) L: Apply a non-permanent locking agent. 7-4 ENGINE REMOVAL/INSTALLATION Special Tool Alignment Jig:. 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 Trans- mission chapter) Carburetor (see Fuel System chapter) Link Bracket A. 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 brack- ets B on the swingarm. Tighten the rear axle bracket bolts C lightly by hand.

ENGINE REMOVAL/INSTALLATION 7-7 Engine Removal/Installation. ENGINE BOTTOM END 8-1 Engine Bottom End Table of Contents Exploded View.Specifications. Special Tools.

Crankcase Cover.Crankcase Cover Removal.Crankcase Cover Assembly.Crankcase Cover Installation. Camshaft and Tappets.Camshaft, Tappet Removal.Camshaft, Tappet Installation. Camshaft Disassembly. Camshaft Assembly.

8-2 ENGINE BOTTOM END Exploded View. ENGINE BOTTOM END 8-3 Exploded View Torque Fastener Remarks Nm kgfm ftlb Connecting Rod Big End Cap Bolts 0.60 52 inlb Breather Valve Screw 0.35 30 inlb Oil Filter Joint 0.70 61 inlb Oil Line Plugs 0.40 34 inlb Crankcase Cover Bolts 21.6 Engine Oil Drain Plugs 0.70. 8-4 ENGINE BOTTOM END Specifications Item Standard Service Limit Camshaft and Tappets Cam Lobe Height: 29.955 ∼ 30.045 mm Inlet 29.86 mm (1.176 in.) (1.179 ∼ 1.183 in.) 29.955 ∼ 30.045 mm Exhaust 29.86 mm (1.176 in.) (1.179 ∼ 1.183 in.) Camshaft Journal Diameter: 19.967 ∼. ENGINE BOTTOM END 8-5 Specifications Item Standard Service Limit 27.4 ∼ 27.7 mm Connecting Rod Big End Width 27.0 mm (1.079 ∼ 1.091 in.) (1.063 in.) 28.0 ∼ 28.2 mm Crankpin Width 28.4 mm (1.102 ∼ 1.110 in.) (1.112 in.) Connecting Rod Big End Inside Diameter 43.004 ∼. 8-6 ENGINE BOTTOM END Special Tools Piston Ring Compressor Grip: Bearing Driver Set: 80 ∼ 91: Piston Ring Compressor Belt,.

ENGINE BOTTOM END 8-7 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.

2016 Kawasaki Mule 610 Service Manual

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. ENGINE BOTTOM END 8-9 Camshaft and Tappets. Install the crankcase cover (see Crankcase Cover Instal- lation). 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. 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: 29.955 ∼ 30.045 mm (1.179 ∼ 1.183 in. ) Inlet 29.955 ∼. ENGINE BOTTOM END 8-11 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. 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. ENGINE BOTTOM END 8-13 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. 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, re- place both the piston and piston rings. ENGINE BOTTOM END 8-15 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. 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. ENGINE BOTTOM END 8-17 Crankshaft and Connecting Rods Connecting Rod Removal. Refer to the Piston Removal for the connecting rod re- moval. Connecting Rod Installation.

Refer to the Piston Installation for the connecting rod in- stallation. Crankshaft Removal. 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. ENGINE BOTTOM END 8-19 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 speci- fied torque (see Piston Installation in the Engine Top End chapter). 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) 35.002 ∼. ENGINE BOTTOM END 8-21 Balancer Shaft Balancer Shaft Removal.

Remove: Crankcase Cover (see Crankcase Cover Removal) Balancer Shaft A Balancer Shaft Installation. Install the balancer shaft to the balancer shaft bearing on the crankcase.

Install the crankcase cover (see Crankcase Cover Instal- lation). 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. ENGINE BOTTOM END 8-23 Breather Breather Valve Removal.

Remove the cylinder head assembly (see Cylinder Head Assembly Removal in the Engine Top End chapter). Unscrew the breather valve screw A. Breather Valve Installation. Install the reed valve A and back plate B, Then tighten the breather valve screw C. TRANSMISSION 9-1 Transmission Table of Contents Exploded View.2WD/4WD Shift Mechanism Specifications.Removal.9-28 Special Tools.2WD/4WD Shift Mechanism Transmission Oil.

9-10 Inspection.9-28 Transmission Oil Level Inspection 9-10 Differential Gears and Shift Transmission Oil Change. 9-10 Mechanism.

9-2 TRANSMISSION Exploded View. TRANSMISSION 9-3 Exploded View 1. Differential Shift Cable 2. Transmission Cable 3. 2WD/4WD Shift Cable (KAF400-A/C) R: Replacement Parts. 9-4 TRANSMISSION Exploded View. TRANSMISSION 9-5 Exploded View Torque Fastener Remarks Nm kgfm ftlb Transmission Cable Holder Bolts 41.5 Connecting Plate Bolts (M8) Connecting Plate Bolts (M10) Transmission Case Bolts 0.90 78 inlb Speed Sensor Cap Bolt 0.90 78 inlb Transmission Oil Drain Plug Cover Screws 0.40 35 inlb.

9-6 TRANSMISSION Exploded View. TRANSMISSION 9-7 Exploded View Torque Fastener Remarks Nm kgfm ftlb Differential Gear Housing Bolts 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. 9-8 TRANSMISSION Specifications Item Standard Service Limit Transmission Oil Type API 'GL-5' Hypoid gear oil – – – Viscosity SAE90: above 5°C (41°F) or – – – SAE80: below 5°C (41°F) Capacity: KAF400-A/C 2.4 L (2.5 US qt) – – – KAF400-B 2.2 L (2.3 US qt) –. TRANSMISSION 9-9 Special Tools Outside Circlip Pliers: Socket Wrench, Hex 41: 57001-144 Oil Seal & Bearing Remover: Alignment Jig: Bearing Driver Set:. 9-10 TRANSMISSION Transmission Oil CAUTION Vehicle operation with insufficient, deteriorated or contaminated transmission oil will cause acceler- ated wear and may result in transmission failure.

Transmission Oil Level Inspection NOTE ○ If the vehicle has just been used wait several minutes for all the oil to settle down.