PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

(US Model only)

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

LIST OF ABBREVIATIONS
A ampere(s) Ib pound(s)
ABOC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATOC after top dead center N newton(s)
BBOC before bottom-dead center Pa pascal(s)
BOC bottom dead center PS horsepower
BTOC before top dead center psi pound(s) per square inch
"C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TOC top dead center
"F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) 0 ohm(s)
L liter(s)

Read OWNER'S MANUAL before operating.

 Foreword
This manual is designed primarily for use by
How to Use this Manual
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic
information to make it useful to the owner who In preparing this manual, we divided the product
desires to perform his own basic maintenance and into its major systems. These systems became the
repair work. A basic knowledge of mechanics, the manual's chapters. All information for a particular
proper use of tools, and workshop procedures must system from adjustment through disassembly and
be understood in order to carry out maintenance and inspection is located in a single chapter.
repair satisfactorily. Whenever the owner has The Quick Reference Guide shows you aU of the
"insufficient experience or doubts his ability to do the product's system and assists in locating their
work, all adjustments, maintenance, and repair chapters. Each chapter in tum has its own compre-
should be carried out only by qualified mechanics. hensive Table of Contents.
In order to perform the work efficiently and to The Periodic Maintenance Chart is located in the
avoid costly mistakes, read the text thoroughly General Information chapter. The chart gives a time
familiarize yourself with the procedures before schedule for required maintenance operations.
starting work. and then do the work carefully in a If you want spark plug information, for example,
clean area. Whenever special tools or equipment are go to the Periodic Maintenance Chart first. The chart
specified, do not use makeshift tools or equipment. tells you how frequently to clean and gap the plug.
Precision measurements can only be made if the Next, use the Quick Reference Guide to locate the
proper instruments are used, and the use of substi- Electrical System chapter. Then, use the Table of
tute tools may adversely affect safe operation. Contents on the first page of the chapter to find the
For the duration of the warranty period, Spark Plug section.
we recommend that all repairs and scheduled Whenever you see these WARNING and
maintenance be performed in accordance with this CAUTION symbols, heed their instructions! Always
service manual. Any owner maintenance or repair follow "safe operating and maintenance practices.
procedure not performed in accordance with this
manual may void the warranty. , ... WARNING
To get the longest lile out of your vehicle:
• Follow the Periodic Maintenance Chart in the This warning symbol identifies special
Service Manual. instructions or procedures which, if not
.Be alert for problems and non-scheduled mainte- correctly followed, could result in personal
nance. injury, or loss of life.
• Use proper tools and genuine Kawasaki vehicle
parts. Special tools, gauges, and testers that are
necessary when servicing Kawasaki vehicles are CAUTION
introduced by the Special Tool Catalog or Manual.
Genuine parts provided as spare parts are listed in This caution symbol identifies special
the Parts Catalog. instructions or procedures which, if not
.Follow the procedures in this manual carefully. strictly observed, could result in damage to
Don't take shortcuts. or destruction of equipment.
• Remember to keep complete records of mainte-
nance and repair with dates and any new parts
installed.
 This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of infonnation.

NOTE
e This note symbol indicates points of partic-
ular interest for more efficient and convenient
operation.
• Indicates a procedural step or work to be done.
e Indicates a procedural sub-step or how to do the
work of the procedural step it follows. It also
precedes the text of a NOTE.
* Indicates a conditional step or what action to take
based on the results of the test or inspection in the
procedural step or sub-step it follows.
In most chapters an exploded view illustration of
the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specifi~
tightening torque, oil, grease or a locking agent
during assembly.
 GENERAL INFO'RMATION 1-1

Gene,rallnformation
Table of Con,tents

Before Servicing ............... ,.......................................................................... "" .............1-2

M,odelldentification ......"...... "....................;....................".............".................."...........1-4
Genera,1 Specifications, ....... ,...".........."' .................................."' ......"........... "' ............... ",,1-6
Periodic Maintenance Chart ." .......................................... "' .... "' .. "''''.......".....................1-7
To'rque and Lock,ing Agent ...".................."' ......,...................................."'....... "'........"' .•1-9
Special Tools, Sealant .................. "........... "' ............................."....................".......... ,..1-12
Cable, Wire, Hose, and Pipe Routing ... "..............................."" ....................................1-16
1-2 GENERAl INFORMATION
Before Servicing

Before starting to service a viehicle, careful reading of the appliicablesection is recommended to eliminate
unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been
included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of ba.sic
knowledge is also required for suocessful WOlrk.

Especially note the following:

(1) Dirt
Before removal and disassembly, clean the vehicle. Any dirt ,entering the ,eng.ine or other parts will work
as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean
off any dust or metal filings.
(2) Battery Ground
Remove the ground (-) lead from the battery before performing any disassembly operations on the
vehicle. This prevents:
(a) the possibility of accidentally tuming the engine over while partiaUy disassembled.
(b) sparks at electrical connections which wiUoccur when they a.re disconnected.
(c) damage to electrical parts.
(3) 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 evenly in a cross pattern. This is to avoid distortion of the part and/or
causing ,gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them
by about a quarter of turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must
be tightened in the order and method indicated.
(4) Torque
When torque values are ,given in this Service Manual, use th,em. Either too little or too much torque may
lead to seri,ous damage. Use a good quality, reiliable torque wrench.
(5) Force
Common sense· should dictate how much fo~ce is necessary in assembly and disassembly. If a part seems
especially difficult to remove or install, stop and examine what may be causing the problem. Whenever
tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an :impact driver for screws
(particularly for the removal of screws held by a locking agent) iii order to avoid damaging the screw heads.
(6) Edges.
Watch for sharp edges, especia:11y during major engine disassembly and assembly. Protect your hands
with gloves or a piece of thick cloth when lifting the engine or turning it over.
(7)' High Flash-Point Solvent
A high flash-point solvent is recommended to reduce fire danger. A commerc.ialsolvent commonly
avail'ab/e in North America is Stoddard solvent (generic name). Always follow manufacturer and container
directions regarding. the use of any solvent.
(8) Gasket, O-Ring
00 not reuse a gasket or O-,ring once it has been in service. The mating surfaces around the gasket should
be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
('9) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer'S directions toir cleaning and prepa.ring surfaces where these compounds will be
used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An
example of a non-pennanent locking agent commonly available in North America is Loctite Lock'n Seal
(Blue).
(10) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on .its outer
or inner circumference so that it will go into place smoothly.
(11) Ball Bearing
When installing a ba,1I bearing,. the bearing race which is affected by friction should be pushed by a
suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being
dented. .Press a ban bearing until it stops at the stop in the hole or on the shaft.
 GENERAL INFORMATION 1-3

(12) Oil Seal and Grease Seal

Repla,ce any oil or grease seals that were removed with new ones, as removal generally damages seals.
When pressing ina seal which has manufacturer's marks, press it in with the marks facing out. Seals
should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the
face of the sea.1 is even with the end of the hOile . .
(13) Seal Guide
A seal guide is required for oertain oil. or grease seals during installation to avoid damage to the sea.llips.
Before a shaft passes through a seal, apply a little oil. preferably high temperature grease on the lips to reduce
rubber to metal friction.
(14) Circlip, Retaining Ring
R,eplace any circlips and retaining rings that were removed with new ones, as removal weakens and
defonns them. When installing circlipsand retaining rings. take care to compress or expand them only
enough to install,1 thernand no more.
(15) Cotter Pin
Replace any cotter pi.ns that were removed with new ones,. asl'8ll1CMll defoinns and breaks them.
(16) Lubrication
Engine wear is general,1y at its maximum while the engine isw.ming up and before all the rubbing
surfaces have an adequatelubricatiw film. During assembly. oil or gr8IIS8 (whichever is more .suitable)
should be applied to .any rubbing surface which has lost its lubrica:tMI film. Old grease and dirty oil should
be cleaned off. Deteriorated grease has kJst its lubricatiw quality and may cootain abmive foreign particles.
Don't use just any oil or grease. Some oils and greases in panicut. should be uSed only in.cerrain
applications ,and may be han'nful if used in an application fo,r which they are not intended. This manl,lal
makes reference to molybdenuml disulfide grease ( MoS2.) in the assembly of certain engiineand ,chassis
parts. Always check manufacturer recommendations before using such special lubricants.
(17) Electrical Wires
All the electrical wires are either single-colloror two-color and. with only a few exceptions, must be
connected to wires of the same colior. On any of the two-color wires there is a greater amount of one color
and a lesser amount of a second color, so a two-c910r wire is identified by first the primary co!lor and then
the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellowIred" wire;
it would be a "red/yellow" wire if the colors were reversed to ma!ke Ired the main color.

Wire (cross-section) Name of Wire Color

Red
Wire Strancls
Yellow/Red
Yellow
Red

(18) Replacement Parts

When there is a replacement in$1J'Uction, replace these parts with new ones 'every time they are removed.
These repla6"ernent parts will be damaged or lose their original function once removed.
(19) Inspection
When parts have been disassembted, visua:.11y inspect these parts for the following conditions or other
damage. If there is any doubt as to the condition of them, replacethern with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20) Specificatio,ns
Specification terms are defined as follows.
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. 'If the measurement shows excessive wear or deteriorated
performance, replace the damaged parts.
1-4 GENERAL INfORMATION
Modell Identification

,KAFI2O-A1 :

KAF820-81:
 GENER.AL INFORMATION 1-5
General Specifications

Item KAF620-A1, A2/B1, 82

Dimensions::
Overall length 2845 mm
Overall width 11460 mm
Overall heiight (A)1 920 mm. (B}1 900 mm
Wheelbase 1870.mm
Track: Front· 1160 mm
Rear. 1180 mm
Ground clearance 170mm
Seat height (A)870 mm, (B)850 mm
iDryweight (A)537 kg, (B)501 kg
Curb weight: Front (A)243 kg, (B) 222 kg,
Rear (A}318 kg, (B)303 kg
Fuel tank capacity 20 L
Cargo bed (L x W x H) 1175x1310x250mm
Performance:
Minimum tuming radius 3.4m
Engine:
Type 4·stroke, OHV, V2·cvlinder
Cooling system Liquid-cooled
Bore and stroke 76.0 x 68.0 mm
Displacement 617mL
Compression ratio 10.3
Carburetion system Carburetor, M ikuni BV26-18
Starting system Electric starter
Igniti!on .system Battery and transistor
Ignition timing 20· BlDC (constant)
Spark plug NG!I< BMR2A
CyHnder numbering method Front to rear, 1 - 2
Firing order 1-2
Valve tilning:
Inlet Open: #1 68° BTDC
#2- 64" BTDC
Close: #1 76· ABDC
#2 B<rABDC
Duration 324"
Exhaust: Open 94" BBDC
Close ,48" ATOC
Dura,tion :322"
Lubrication system Forced lubrica,tion (wet sump)
Engin~ oil:
Grade I SE or SF class
Viscosity SAE10W·40, 1 OW-50, 20W-40, or 20W·50
Capacity 1.8 L
1-6 GENERAL INFORMATION

Item KAF620-A1. A2/B1, B2

Drive Train:
Primary reduction system:
Type Selt drive torque converter
Reduction ratio 3.5 - 0.98
Transmission gear ratio:
Forward (A) 1.821 (51/28): High
(Al 3.750 (51/28 x 25/20 x 28117): Low
(8) 1.821 (51/28)
Reverse (A)2.050 (41/20): High
(A)4.220 (41/20 x 2S/20 x 28/17): Low
(8)2.050 (41/20)
Final drive system:
Type (A) Gear (4WO/2WO), (B) Gear (2WO)
Reduction ratio 5.4 (81/15) .
Overall drive ratio:
Forward (A)9.639: High, (A)19.84S: Low, (8)9.639
Reverse (A)10.848: High, (A)22.335: low, (S)10.848
Transmission oil:
Type API "GL-S" Hypoid gear oil
SAE90 : above 5"C (41°F)
SAESO : below 5°C (41°F)
Capacity . (A).2.Sl, (8)2.2 L
Front final gear case oil (KAF620A):
Type API "GL-S" Hypoid gear oil for LSD
SAE140 or SAE85W-140 .
Capacity 0.2L
.Frame:
Type Steel tube, Ladder
Caster (rake angle) 7.5"
Camber 0.8"
Trail 35mm
Tite: Front and rear (A) 22 x 11.00-10, Tubeless
(8)20 x 10.00-10, TubeleSs
Steering type Rack and pinion
Suspension:
Front Type MacPherson strut
Wheel travel 100 rnm
Rear~ Type De Dionaxle
Wheel travel 70mm
Brake type: Front and rear Drum (Hydraulic)
Parking brake type Drum (Mechanical internal expansion)
Electrical Equipment:
Battery 12V19Ah
Headlight:
Type Sealed beam
Bulb 12V35Wx2
Tail/brake light 12V S/21 W
Alternator:
Type Single-phase AC
Rated output 14.7 A @4 000 rlmin (rpm), 14 V
load Capacity:
Maximum vehicle load
(including occupants and cargo) 603 kg
Maximum cargo bed load 364 kg

Specifications are subject to change without notice, and may not apply to every country.
 GENERAL INFORMATION 1-7
Periodic Maintenance Chart

The schedul,ed maintenance must be done in accordance with this chart to keep the vehicle in good running.
condition. The first service is vitally im,portant and must not be neg.lected.

Whichever' First Regular Se!l'Viioe

I

FREQUENCY comes first . Service

!
-+ After !
Every Every
I
I
t 50 h, or 250 h, or 500 h, or
OPERATION Every 1 000 km 5000 km 10000 km
of use of use of use
ENGINE
Converter beb--check*
•
Converter driven pulley shoe- -check·
• I

I
Spark plug--clean and gap
•
Air cleaner element--clean*
• •
Valve clearance--check
• • il
Engine oil--change* 1 year
• • ,I

Oil filter- -replace*

• • :1

:
Throttte pedal play--check
• •
I Idle speed--adjust c

• •
I
Fuel system cleantiiness- -check" I • I

•
I

Spark arrester--clean I I

• •
I
Radiator--clean *
I

I
Radiator hoses and connections--check* 1 year !I • •
Coolant--change 2 years
Fuel hose- -replace 4 years

•. = Clean, adjust, lubricate, torque, or replace parts as necessary

* = Service more frequently when operated in mud, dust or odler harsh riding conditions.
1-8 GENERAL INFORMATION

Whichever First 1 Regular Serviice

FREQUENCY comes f,ilSt Service
... After Every Every
1 50 h•. or 250 h. or 500 h. or
OPE!RATION ,Every 1000km 5000km 10 000 km
of use of use of use
CHASSIS
Steering--check • •
•
,

•
I
Steering joint dust boots- -check
I
,
Brake pedal pllay--check" I • ,

•
I Parking brake lever--check. I
• • I

• •
,
Brake hose and pipe--check .,

Brake fluid level--check I

• I

•
Brake wear--check:" ,
•
\ Tire wear--check* • •
Battery- -check •
Brake light switch--check • •
Seat belt- -check •
Generallubrication--perform" •
Bolts. nuts, and fasteners tightness- -check • •
Wheel nuts tightness--check • •
Front final gear case oil (KAF620A)
and transmission oil--change*
I
1 year
• •
Brake f1uid--change 2 years
Brake master cylinder cup and dust seal--replaoe 2 years
Brake wheel cylinder assembly- -replace 2 years
Brak.e hose--ireplace 4 years

• = Clean, adjust. lubricate, torque. or repfaceparts as necessary

" - SElrvice more frequently when oper:ated in mud, dust, or other harsh riding conditions.
 GENERAL INFORMATION '-9
Torque and lock.iing 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.

Letters used in the "Remarks" column mean:

L : Apply a non-permanent locking ag,entto the threads.
o : Apply an oi'l to, the threads. seated surface, or washer.
5 : Tighten the fasteners following the specified sequence.
55: Apply a silicone sealant to the threads.

I
Fastener Torque I Remarks
,

N-m kg-m ft-Ib

I
Fuel System:
Car:buretor mounting bolts 15 1.5 11.0
Carburetor throttle valiYe mounting screws - - - L
'Carburetor choke valve mounting. screws - - - L
Carburetor float bowl mounting bolt 7.8 0.80. 69 in-Ib
Carburetor holder mounting bolts - - - L
,
Governor arm clamp nut , 7.4 0.75· I
65 in-Ib
i
, Cooling System~ i
i
, Radiator fan switch 25 2.5 18.0
Coolant temperature switch - ,
- - 55
Water pump cover bolts 8.8 0.90 78 in-lib
Engine Top End:
Cylinder head bolts 22 I
.2 ..2 16 . 0. 5
ValVe adjusting. screw locknuts 9.8 1'.0. 87in-lb
Muffler mounting bolts - - - L
Converter System: I
I
,
Converter oover bolts 1.5 0..15 13 in-Ib
I
Drive pulley bolt 93 9.5 , 69
Driven pulley bolt I 93 9.5 69 L
Drive pulley cover bo:1ts 13 1.3 113 in-Ib
i
Ramp weight shaft stop bolts 13 1.3 I
113 in-Ib
I
Ramp weight roller sha.ft stop bolts 13 1.3 113 in-Ib
Driven pulley coupling bolts 13 1.3 113 in-Ib
i
Engine Lubrication System:
Engine oil dr:ain plug: 14mm dia. 22 2.2 16.0
16 mmdia. 25 2.5 18.0
Oil pressure switch - - - 55
. Engine Bottom End:
Crankcase cover bollts 22 2.2 I
16.0
I
Connecting rod big end cap bolts 21 2.1 15.0
Transmission:
!
Tr:ansmission case mounting nuts 44 I
4.5 33
nansmission oil drain plug 15 1.5 11.0
Transmission case bo,1ts 8.8 0.90 78 in-Ib
I Neutr:al switch 15 1.5 11 . 0
Transmission shift arm positioning bolt 37 3.8 .27
Differential shift shaft stop bolt ,
7. 8 0.80 69 in-lib
1-10 GENERAL INFORMATION

Fastener Torque Remarks

N-m kg-m ft.-Ib
.2WD/4WD shift shaft stop bolt (KAF620A) 7.8 0.80 69in-lb
Differential gea,:r housing bolts 29 3.0 22 L
Hi/low gear case bo'its (KAF620A) 20 2.0 14.5
Drive bevel gear shaft bearing holder 120 12.0 87 0
(KAF620A)
Wheel.s/Tires:
Wheel nuts 98 10.0 72
Fina.1 Drive:
Front final gear case (KAF620A):
I
Mounting nuts 44 4.5 33
,
Bracket bolts 44 4.5 33 l
Oi'l filler cap 29 3.0 22 ,

Oil drain plug 20 2.0 14.5

I
Drive shaft cap bolts 8.8 0.90 78in-lb
Ring gear cover bolts: 10 mm dia. 47 4.8 35 ,
,
8mmdia. 25 2.5 18.0
Ring gear bolts 49 5.0 36
Differential case tal)( bofts 32 3.3 24 L
Pinion gear slotted nut 120 '. 12.0 87 0
Pinion gear bearing housing nuts 25 2.5 18.0
Beve'l gear assembly mounting bolts
!
(KAF620A) 22 2.2 16.0
Drive bever gear mounting nut (KAF620A) 120 12.0 87 0
Driven bevel gear retaining nut (KAF620A) 110 11.0 80 L
,

'Driven bevel gear shaft assembly

bearing holder (KAF620A) 120 12.0 87 L ,

Driven bevel gear shaft assembly

housing locknut (KAF620A) 120 12.0 87 L
Driven bevel gear shaft assembly
holder nuts (KAF620A) 25 2.5 18.0
,
Brakes:
Master cylinder reservoir clamp boht 5 ..9 0.60 52 in-Ib
Master cylinder pi.ston stop bolt 8.8 0.90 78 in-Ib
Master cylinder push rod locknut 18 1.8 13.0
Brake hose banjo bolts 25 2.5 18.0
Brake pipe nipples 18 1.8 13.0
Axle nuts 195 20.0 145
Brake panel mount,ing bo,lts 44 4.5 33
Wheel cyHnder mounting bolts and nuts 7;8 0.80 69 in-Ib
Bleed valves I 5.9 0.60 52 in-Ib
 GENIERAllNFORMATIONi 1: ·11

Fastener Torque Remarks

I
N-m kg-m ft-.lb
Suspension:
I
Strut (Front shock absorber): I
I,

Upper mounting nuts 44 4.5 33 I

II ,
Lowercl.amp nuts 98 10.0 72
Front suspension arm pivot bolts 98 10.0 72
Front .suspension arm joint nuts 78 8.0 58 ,
I
Rea:, shock absorber mounting nuts 44 4.5 33
Leaf spring; mounting nuts: Front 98 10.0 72
Rear 59 6.0 43
I Damper bracket mounting nuts 44 4.5 33
Steering: ,

Steering wheel mounting nut 52 5.3 !

38 I
Intermediiate shaft clamp bolts 20 2.0 14.5 I
I
I
Steering gear assembly bracket. bolts 52 5.3 38
I
I
Steering gear tie-lrod end locknuts 49 5.0 ! 36
Steering gear tie-Irod end nuts 34 3.5 I 25
Steering gear rack guide spring cap locknut 39 4.0 2.9
'Frame: -
Seat belt mounting bo,1ts 34 3. 5 25 !
I

Front bar mounting .bolts:

Lower 145 15.0 11:0
Upper 44 4.5 33 i

Rear bar mounting bolts and nuts 44 4.5 33 I

Rear end sub-frame mounting nuts 44

I
4.5 33
Elect!rical System:
Spark plugs 17 1.7 12.0
Altemator rotor nut 120 12.0 87
Alternator stator mounting screws - - - L
Starter motor lead terminal nut 8.8 0. 90 78 in-Ib

The table below, relating. tightening torque to Basic Torque lor General' Fasteners
thread diameter, lists the basic torque for the bolts
Threads dia. Torque
and nuts. Use this table for only the bolts and nuts
which do not require a specific torque value. AU of (mm) N-m ikg-m ft-Ib
the values are for use with dry solvent-cleaned 5 3.4 - 4.9 0.35 - 0.50 30 -43 in-Ib
threads. ,
6, 5.9 -7.8 0:,60 "" 0.80 52 - 69 in-Ib
8 14 -19 1.4"" 1.9 10.0 - 13.5
10 25 - 34 2.6"" 3.5 19.0 - 25.0
12 44 - 61' 4.5,",6.2 33 -45
14 73 - 98 7. 4"" 10.0 54 -72
16 115 -155 11.5 - 16.0 83 -115
18 165 - 225 17.0 - 23.0 125 -165
20 225 - 325 23 - 33 165- 240
1-12 GENERALINFORMATION
Special Tools, Sealant
Pressure Cable Luber: K56019-021 Bearing Driver: 57001-382

Piston Ring Pliers: 57001 -115 Piston Pin Puller Assembly: 57001 -91 0

o
o
o

Bearing Pul,ler: 57001-135 Hand Tester: 57001-1394

Inside CirclipPliers: 57001 -143

Outside Circlip Pliers: 57001 -144 Oil Seal & Bearing RemiOYer: 57001-1058
 GEN,ERAL INFORMATION 1-13

Piston Ri'ng CompressOir Grip: 57001-1095 Bearing Driver Set: '57001 -1129

Piston Ring Compressor Belt fl>67 - <J)79: 57001 -1 09'7 Valve Seat Cutter, 45" - ¢l30: 57001 -1187

Valve Seat Cutter, 45° - «1>35: 57001 -1116 Hexagon Wrench. Hex 32: 57001-1194

Valve Seat Cutter, 32° - «1>30: 57001-1120 Valve Seat Cutter, 32" - «1>33: 57001 -1199

V,alve Seat Cutter Holder Bar: 57001 -112.8 Rotor ,Puller, M16/M18/M20/M22 x 1.5: 57001-12.1'6
1-14 GENERAL INFORMATION

Valve Adj usting Screw Holder. 57001 -1217 Pinion Gear Holder: 57001 -1281

Clutch Holder: 57001-1243 Socket Wrench: 57001-1283

Oil Fater Wrench: 57001.-1249 ,Pinion Gear Holder: 57001-1285

Brake Drum Remover: 57001-1260 Flywheel Holder: 57001 -1313

Brake Drum Pusher: 57001-1261 Hexagolll Wrench, Hex 40: 57001 -1324
 GENERAL INFORMATION 1-15

Brake Drum Holder: 5700' -1325 Assembly Jig: 57001 -1365

Brake Drum Remover Nuts: 57001-'326 Kawasaki Bond (Silicone Sealant): 56019-120

Valve Seat Cutter Holde/:. (JI6: 57001-1360 Kawasaki Bond (Liquid Gasket - Silver): 92104-002

Socket Wrench: 57001-1363

NOT:E
o Use the following tools only for the KAF620A.
57001-135
57001-382
57001-1049
57001-1194
57001-1281
57001-1283
57001-1285
57001-1324
Transmissiion Gear Holder: 57001-1364 57001-1363
57001-1364
1-16 GENERAL INFORMATION
Cable, Wire, Hose. and Pipe Routing

1. 'Hi/Lo'w Shift Cable (KAF620A)

2. Transmission Shift Cable
3. Throttle Cable
4. Differential Shift Cable
5. Choke Cable
6. 2WDl4WO Shift Cable (KAF620A)
7. 'Parking Brak,e Cable
8. Parking Brake Cable (Left)
9. Park.ing Brake Cable (Right)
10. Brake Pipe
11.. Main· Harness

V16wed from A

.}---0
®
10
®
@)
® Viewed from B
 GENERAL INFORMATI'ON 1-17

, ., Horn Button IKAF620BI

2. I·nstall horn button with lead coming rearward.
3. Horn iLeadlKAF620BI
4. Main Harness
5. Choke Cable
6. ·Differential Shift Cable
7. Radiator Fan Motor Breather Hose
8. Brake Light Switch
9. Radiator Fan Leads
, O. Radiator Fan Switch Leads
11. Throttle Cable
12. Brake Pipe
13. Transmission Shift Cable
14. Hi/Low Shift Cable (KAF620A)
15. Front Final' Gear Case Breather Hose (KAF620A)

@ Viewed from A
 15. Main Harness
......•
CD
1. 110mm 16. Battery (-) Leeds (Black Tape) Ci)
2. Hom (KAF620B) 17. Battery (+) Lead. (Red Tepe) m
3. Radiator Fan Switch Leads 18. Parking Brake Light Switch Lead Z
4. Brake Light Switch Leads
m
19. Ground Lead (Engine) :II
6. Cooling Temperature Werning Light Leods 20. Starter Motor Lead >
r-

r~
6. Fuel Pump
7. Tape Side Z
."
8. 100mm
9. Noutral Switch Lead
o:II
(J)
10. Ground Lead (Frame) ~
11 . 50mm or More
~
12. Igniter
13. Tape Side
o
z:
14. Position Mark (White Tape)
 GENERAL INFORMATION 1-19

1. Brake Master Cy:linder

2. Keep hose away from steering intermediate shaft .
3. Install clamp in this direction.
4. Brake Hose (Left)
5. Rediator Fan Motor Breather Hose
6. Front Fender Lower
7. Radiator Fan Motolr
8. Reservoir Tank
9. Run overflow hose through bracket hole.
10. Reservoir Tank Overflow Hose
11. FlJel PlJmp Breather Hose
12. FlJel Pump

Viewed wom, Top

~-------

Viewed from Top

1-20 GENERAL IN,FORMATION

Water Hoses for Carbur,etor

1. Carburetor
2. Hose Fitting
3. 15·

@)
 FUEL SYSTEM 2-1

Fuel System
Table of Contents

Exploded Viwt ..........................................................2-2 Choke Cable Inspection .......................................2-9

Specifications ••.......................•......................•....•...•..2-4 Carburetor..•........•..•.................................................2-10
Throttle Pedal and Cable ...•....••..•..........................•...2-5 Idle Speed Inspection ................_........................2-10
Throttle Pedal Free Play Inspection .................•...2-5 Idle Speed Adjustment... ..........................•........ .2-10
Throttle Pedal Free Play Adjustment....................2-5 Fuel System Cleanliness Inspection .......•..........2-10
Full Throttle Pedal Position Adjustment .••.•....••.. .2-5 CarbuIlllOr RemovaL.........................................2- 11
Throttle Cable Installation ....................................2.6 Carburetor Installation ........................................2-11
Throttle Cable lubrication ••.•••.•...•.........................2-6 Carburetor O~bly/Assembly ....•...............2-12
Throttle Cable Inspection ...............................__ ... .2-6 Carburetor Oeaning ...........................................2-12
Govemor link Mechanism .•...............•.••...............•...2-7 Carburetor Inspection ...........................•.............2-13
Control Panel Assembly Removal... .•...............••.•2-7 Air Cleaner .................;...•.•..•.••......•...•••...•..•..•..•....•. 2- 14
Control Panel Assembly Installation ....................2-7 Air CI_er Element Rernoval... ......................... .2-14
Governor Ann and Throttle link Rernoval. ......•...2-7 Air Cleaner Element Cleaning{lnspection ..........2-14
Governor Ann Installation ............•..•...•...•...•........2-7 Fuel Pump and Fuel Filter..................................•....2-15
Govemor Assembly Removal ....•..........................2-8 Fuel Pump and Fuel Filter Removal ...................2-15
Governor Assembly Installation ...........................2-8 Fuel Pump Installation ...................•...................2-15
Governor Assembly Inspection ............................2-8 Fuel Filter Installation .........................................2-1 5
Choke Cable ..............•..•..•....•.................................•..2-9 Fuel Filter Inspection ............................•.....•.......2-15
Choke Cable Free Play Inspection ........•...•........•.2-9 Fuel Tank ..........._•.....................•......••..........•...........2.-16
Choke Cable Free Play Adiustment ................•....2-9 Fuel Tank Removal .............................................2 -16
Choke Cable Installation ......................................2-9 Fuel Tank Installation .........................................2-16
Choke Cable Lubrication ...................................•.. 2-9 Fuel Tank Cleaning/lnspection ..........................2-16
2-2 FUEL SYSTEM
Exploded View

AD : Apply adhesive agent.

G: Apply gll88Se.
L : Apply non-permanent locking agent.

1'1 : 7A N-m (0'.75 kg-m. 85 In-Jb)

I 12: 7.8 N-m (O" kg-m, &tln-Ib)
13: 15 N-m (1.5 kg-m. 11.0' ft-Ib)

•v •
~

/~
---'

t
 FUEL SYSTEM 2-3

G3
~$f~
.. I
nU ~.
• I " .,
W·
~
.2-4 FUEL SYSTEM
Specifications

Item Standard Service Limit

Throttle Pedal and Cable:
Throttle pedal free play 5 -10mm - --
Choke Cable:
Choke cable free play 2 - 3,mm - --
Carburetor:
ldlespeed 900 - 950 r/min (rpm) -. --
Carburetor specifICations:
Make/type Mikuni/BV26-18 - --
Main jet #115 - --
Pilot jet #4IJ , - --
Main nozzle 848 - --
Pilot screw 1Y.itumsout - --
I
 FUE.L SYSTEM 2-5
Throttle Pedal and Cable

Throttle Pedal Fr:ee Play Inspection

eCheck the throttle pedal free play [A].
*If the free play isinconect, adjust the throttle cable.
Throltle Pedal Free pllay
Standard: 5 - 10 mm

Throttle Pedal Free Play Adjustment

eRemove:
Cargo Bed (tillt up)
eLoosen the adjuster mounting nuts LA] at the cable lower end.
eSllide the adjuster IB] until the proper amount of throttlle pedal free
play is obtained.
eTighten the mounting nuts securely.
• Start the engine.
• With the transmission in neutral, operate the throttle pedal a few times
to make sure that the idle speed does not change.
*llf the idle speed does change, the throttle cable may be improperly
adjusted, incol'l'ectly routed. or it may be damaged.
eCorrectany of these conditions before operation.

OperatIonwllb Improperly ......., .1ncorrec1Iy 'rouIId,

; damaged cable could rreault In anunsale operaIIngconc:llllon.

NOTE
o If the throttle pedal free play cannot be adjusted by using the
adjuster at the cable lower end, use the adjuster [A] at the cable
upper end. Do not forget to securely tighten the adjuster mounting
nuts [8].

Full Throttle Pedal Position Adjustment

eLoosen the locknut [A].
eScrew ,in the throttle pedal stop bolt [8].
e Depress the throttllepedal until the throttle lever on the carburetor is in
the fully opened position, and keep its position .
• Tum the thro,ttle pedal stop bolt unti,( the bolt head lightly touches the
bottom of the throttl!e pedaL
.,Tighten the locknut S6Curely.
2-6 FUEL SYSTEM

Throttle Cable Installation

• Route the throttle cable ,correctly (see the General Infonnation
chapter) .
• Adjust:
Throttl:e Pedal' Free Play Adjustment

Throttle Cable Lubrication

Whenever the Ulrottle cable is removed,. lubricate the cable as follows.
.AppIy a thin coating of grease to the cable upper and lower ends.
• Lubricate the cable with a penetrating rust inhibitor through the
, pressure cable luber.
SpecIal Tool - "..... cable Luber. Ka19-021

Throttle Cable Inspection

.WIth the throttle cable disconnected at both ends, the cable should
move freely 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.
 FU EL SYSTEM 2.-7
Governor Link Mechanism

Control Panel Assembly Removal

• Remove:
Cargo Bed
.Orill out the pop rivets [A] holdill,g the control panel assembly shroud
[B] with a drill! bit of the 5 mm diameter.
o Drill only until the rivet head comes off. Do n,ot drill through the hole.
• Remove:
Control Panel Assembly Mounting Bolts [C] and Collars
Control, Panel Assembly (01

Control Panel Assembly lnstallation

.Turning the control panel assembly counterclockwise, tighten the
assembly mounting boI1s.
• Install the control panel assembly shroud and pop rivet the shroud to
the control panet assembly.
• Adjust
Throttle ;P.edal Free Play Adjustment
Idle Speed Adjustment

Govetnor Arm and Throttle Link R,emoval

• Remove:
Cargo Bed
COntrol Panel Assembly Shroud
Governor Arm [A]
Throttle link [B]

GoVetnOf Arm Installation

.Adjust the governor arm on the shaft.
o Loosen the nut [A)..
OTum the govemor shaft [BJ clockwise as far as possible and hold it
there.
oTum the governor arm IC] clockwise as fa:r as possibile (to make it fully
open the throttle valve [0]), hold it there; and tighten the nut

.Check that thegovemor arm [A] and the accel lever pin (B] fit
together or there is a slight clearance between the govemo,r arm and
the accel :Iever pin, when the throttle lever is fully opened.
2-8 FUEL SYSTEM

Governor Assembly Removsl

.Remove:
Transmission Case (split)
GovemorAnn
Govemor Shaft Snap Pin [A]
Governor Shaft [8]
Washer (thin) [C]
Washer (thick) [D]

.Remove the governor assembly [A] with the sleeve [8] by prying. the
gear [e] with two suitable levers.

·1 Do ... _ ..!!""""*'=_. ._. . ,.

_ II bas bean I'8II1CMId. I must be replaced.
Oncel'
_

• Remove the washer.

Governor Assembly Installation

• F'd: the sleeve into the governor assembly, and install them as a set.
NOTE
o The slesveand the governor aaembIy cannot be iMtaIIed.separately.
OPu$h the sflt onto the shIIIt until the stsp fits into the groove securely.

Sleeve [Al
Governor Assembly [8]
Step[C] .
Washer [0]
Groove[E]
Shaft [F}
32mm [G]
.Check t\:'Iat the gear tums freely and the weights move smoothly.

Governor Assembly Inspection

.Visually check the govemor assembly for wear and damage.
*H any part is worn or damaged, repface the assembly.
 FUEL SYSTEM 2-9
Choke Cable

Choke Cable Free Play Inspection

e Push in the choke knob all the way.
e Check the choke cable free play fA).
o 'Determine the amount ot free play at the choke knob. Pull the choke
knob until the starter lev,er on the carburetor begins to'tum; the amount
of chok.e knob travel is the amount of free play.
* If the free play is not correct, adjust the choke cable.
Choke C8bte Free Play
SIandard: 2 - 3 mm

Choke Cable Free Play Adjustment

eR,emove:
Cargo Bed (tilt up)
e Loosen the m.ounting nuts [A]aod slide the adjuster [8] ulntil the
cable has 1Ihe proper amount of free play.
• Tlghten the mounting nutssecu.,tv.

Choke Cable Installatkm

e Route the choke cable correctly (see the General Information chapter) .
• Adjust
Choke Cable Free Play Adjustment

. OperatIon wllb IIICD1lN011J I'CIUI8d orlmproperty adjUSlacli cable could

result In an, ....... QP8IaIIng condlllon.

Choke Cable Lubrication

Whenever the choke cable is removed, lubricate the cable as follows.
eLubri'cate the cable with a. penetrating rust inhibitor through the
pressure cable luber.
SpecIal ToaI· - ,...... CabIIt Luber: K58O'I9-021i

Choke Cable Inspection

eWith the choke cable disconnected at both ends, the cable should
move freely within the cable housing.
*If the cable does not moye fI'eeIy after lubricating, iifthe cable is frayed,
or if the housing is kinked. r~lace the cable.
2-10 FUEL SYSTEM
Carburetor

Idle Speed Inspectio.n

.Start the ,engine and wann it up thoroughly.
• Tilt up the cargo bed.
• Check the idle speed with a tachometer.
*If the idle speed is out of the specified range, adjust it.
,IdIeSpeed
S1andard: 9GO - 150 r/mln (rpm)

Idle S{J86CI Adjustment

.Start the engill1eand wann it up thoroughly.
eTilt up the cargo bed.
• Loosen the accellever stopper screw [A] on the control panel.
• Tum the idle adjusting screw [Blat the carburetor until the idle speed
is correct
.Openand close the throttle a few times to make sure that the idle
speed is within the specified range. Readjust if necessary.
eAfter the adjustment. screw in the accellever stopper screw [A] until
the screw lightly touches the accellever [C1·

Fuel System Cleanliness Inspection

.."WARNING
GasOline Is exlrenl8lyllamlmlble and can be explosive under certain
condlllons. Tumllhe Ignlllon SWllctli OFF. Do not amok..M._ .....
lie area Is weU-ventllaIed and ..... from, any source of IIame or
sparks; Ihls Includes any ...,.Iance.,111 a. plloIllgM.

.,Remove:
Cargo Bed (tilt up)
ePlace a suitable container under the carburetor.
• Tum out the drain screw [A] a few turns to drain some fuel trom the
carburetor, and check for water or dirt in the fuel.
*If any water or dirt comes out, clean the carburetor and fuel tank (see
Fuel Tank) and check the fuel filter.
• ,Tighten the drain screw securely.
 FUE'L SYSTEM 2-11

Carburetor Removal
AWARNING
Gasoline Is extremely flammable and can be explosive under certain
concIltIOIIII. Tum'" IgnIIIan awllchl OFF.. Do noI smoke. MD.• sure
lie area I8well-venlllatecil and tree from any sourw· offtame or
spatb; IhiIIncIudes 8IIJappllancewilh a pilot IIghL

• Remove.:
Cargo Bed (tilt. up)
Fuel Hose (discoMBCt)
Airl:l'ltake Duct Clamp [A] (loosen)
Carburetor Cover Bolt [B]
Carburetor Mounting Bohs [C]
Carbtlll8tor Cowr [OJ
Carburetor ['E]
Choke Link [F]
.After removing the carburetor, stuff pieces of lint-free, cleanclloth into
the carburetor holder and the air cleaner duct to keep dirt out of the
engine and air cleaner.

I· dirt gel8lhrough lido the engtne, excassiveenglne wear and

possibly engine damage will occur.

Carburetor Installation
.Torque:
To.,.. - Carburetor Moulding Bolls: 15 H-m (1..5 kg-m., 11 J) n-lb)
.Iinstall the choke Ilink [A] as shown.
• Adjust
Throttle Pedal Free Play Adjustment
Choke Cable Free Play .Adjustment
Idle Speed Adjustment
2·12 FUEL SYSTEM

Carburetor DisassBfTlb/y/ Assembly

.. WARNING

GMoIIne,. .ldIemety~ ancteat be exploalve under_In

- - Tum ... /gnIIoII1WIcII OFF. Do not_L _ ......
... .... Is weI~ and _ InIm _ 1GUn:8 aI .....e or
sparb; ..,. IncIudeI .., _ _ _ ..... a pilot I/gIIt.

.Tum in the pilot screw [A] and coum the number oftums until it sealS
fully but not tightly. and then remove the screw. This is to set the
screw to i1S original position when assembUng.
• Tum in the pilot screw fully but not tightly, and then back it out the
same number of turns counted during disassembly.
• Remove the screws and take off the throttle valve [8] and/or choke
IIOlve [C]. The throttle valve shaft has the return spring.
• Appiy non'permanent locking agent:
Thrott1e V2I.ve Mounting ScIl!W$
Choke Valve Mounting Sctews
.Torque:
TCII'qIM - Float Bowl MounIIng loll : 7.8 Nom (0.80 ...." • _I

Carburetor Clesning
..WARNING

__.
CIeu !he CIIltIUr8IOr In a . .,j......18tMI _ ........ C8N . . .
__ Is no epeIIt or ..... ..,."" ...., ... WGftdng .u; til

........ ...
. . - - .., ."pn."c....... pIIoIl/gIIt. 1Iac:aI_ aI\be - . . . aI
highly ...... nebI. Ilqukl8. do not _ g• • 11".
or low IIIIIt point

CNJnON
Do _ _ _...
ad a~ 01\ an _lmbIed carbu_... ..,..
maybearuolladby'" _ _ _• _ _ _ ....., ..-orplaollo
..... Irom ... _ • • N. baIDn e..... '" . . - - . -
willi • cleaning ......aon. 11I1s wIIIprewanI_. or ~1I.rloo"'"
of Ita paoIL 1he _ bodr ha pIaoIIo paotI . . . _ be
removed. Do not _ • eIrang --...... elNr!lnII aolullon which
_Id . . . . _ _ paoII;NIIIIId, . . . . mid 1I/gII1IMII~ ell.",
soIIIIIon . . . let pIaoIIo ......

....., UPI I ." ,*,_..,

Do _ ... wire or .., oilier herd ........... 10 clean ~
may be . . 'II'~

.Oisassemble the carburetor.

• 'mmerse all the me!81 pans in a Clilburetor cleaning solution .
• Rinse the parts in water.
• When the parts are clean, dry them with compressed ail.
• SIow thlough the ail and fuel passages with compl8SS9d ail.
• Assemble the carburetOI.
 FUEL SYSTEM 2-13

Carburetor Inspection

Gasoline Is extremely flammable and ,can be explosive under certain

I conditions. Tum IfIe IgnIIon swIIch OFF. Do, not smoke. Make sure
IfIe area 18 well-venlllaled and he ffom anyllOUl'Ce of name or
........ 1ncIUdeI ............'. pilot light.
.Tum the tluotlle and choke ihafts to cl1eck that. the throale and choke
bunarfty valves ..-smooth:Iy. '
*If the' valves do not mont smoothly. replace the damaged parts.
damaged parts. .
eCheck that the gaskets on the float bowl mounting bolt and the
carburetm bocI¥ .. in good condition.
* If any gaskets are not in good cOndition, replace them.
eChede, the float for:craCks. .
*.f there are any cracks, replace the ftoat
NOTE
o FltMt height CM not bB IIdju$I«I.

.Check the tip of ttle float va,1ve needle. It shouild be, smoo1In, without
any grooves. scratches, or llears.
*If the tip is damaged, repJace the needle.

• Check the tapered portlion of the pilot screw [A] for wear or damage.
*ilf the pilot screw is womn or damaged on the tapered portion [8] it
will prevent the engine from idling smoothly. Replace it
2-14 FUEL SYSTEM
Air Cleaner

Air CI6IJner Element Removal

• Remove:
Seat (tilt up)
Fasteners tAj (unhook)
Air Cleaner Housing Cap [Bj
Element Mounting Screw [C]
Element Clamp Screw [D)
Element [Ej
.After removing the eI~t stuff pieces 01 lint-free. clean cloth in1D the
air cleaner duct 10 keep dirt out 01 the carburetor and engine.

• tilt or cMl Ie ....... to " . . IInIugh II*) h ....... h

1IIRIIIIe...., ~ 1IUc*,~ ........ -'dutl.

1· ... - -..... =-". --..

......., engine dan III W. ocaw. 1

Air Cleaner Element Cleaning/lmpection

NOTE
O/n dusty _the BlenHmt should be ct.ned _ frequently tlllm
the ~ inlllrial.
OAfter riding through rain or on muddy roMs. tile III_I should be
cluf76d immediately.
..,'NARNIM,

a... .......... tn ••• I1 .... ? tWM, . . . . . . . . . . c.e ...

_ _ I10..,.uor_..,_._h-"'-
a-... 01 hdanoW 01 ~ bmmllllie ~ do nat ...
gMOIlna or alow ftuII.1IaInI ooIvant 10 _ .......1In!-
.aemove the air cleaner eiem«lt. and separate the foam element [A]
from the paperelelnent [B) .
• Clean the foam element in a bath of a high flash-pcint solvent. and
then dty it with compnllllled air or by shaking it.
• After cleaning. saturate the foam element with SE class SAE30 oil.
squeeze out the excess. then wrap it in 8 clean rag and squeeze it ~
dry as possible. Be C8IIIfuI not to teer the foam element.
.Clean the paperelemont by tapping genUy or washing in detagentand
water.
NOTE
OAfter woshing. dry thoroughly.

1Donat ... com,..... II.m=: peper.-...L

 FUEL SYSTEM 2-15
Fuel Pum,p and Fuel Filter

Fuel Pump and Fuel Filte! Removal

iJ.WARNING
GasolIne Is extI'emely flammable and can be upIosIve under cerllllA
condIIans.Tum Ihe _ _ 8WIIah OFF. Do not lIIIake. Milke SIft
lINt . . . Is welHentlIlded .and, free from any soun:e. ,of name or
sparks; IhIs Includes any appliance wfth. pilot light.

• Remove:
Cargo Bed (tilt up)
Fuel Hoses (disconnect)
Fuel Pump [AJ
Fuel Filter [8]

Fuel Pump Installation

.Install the rubber damper [A] to the pump so that the projection [8]
on the damper .aligns with the pail;t mark [el on the pump.
• Connect the fuel hose from the filter to,the fitting mallcedl INLET, and
the hose to the carburetor to the another fitting.

Fuel Filter Installation

.Install the fuel filter so that the alTOW [Alan it shows tfIe; fuel flow
from the fuel tank to the fuel pump.

Fuel Filter Inspection

eVisuallyinspect the fuel filter.
*If the filter iscl:ear with no signs ,of dirt or other contamination, it is
OK and need not be.replaced.
*If the filter is dark or looks dirty, replace it Also, check the rest of the
fuel system for contamination.
2-18 FUEL SYSTEM
Fuel Tank

Fuel Tank Removal

~I.WARNING

GaeoIIne ............., ........... and can be expIOIIIve undercartaln

condlllon8. Tum "Ignllon IWIch OFF. Do nat ........... ....
Ihe area .. weII-venIIIaIad and ..... from any ..... GIl .... or
apartrs; .... Incl..... ..., appIIanca .... a plot light.

eRemove:
Cargo Bed (tilt up)
Fuel Hose [A] (disconnect)
Fuel Tank Holder Nuts [B]
Fuel Tank Holders [C]
Fuel Tank [0]
o Slide back the fuel tank and remove it from the vehicle.

Fuel Tank /nstJJIlation

elf the rubber d.npers [E] and/or trim [F] were removed, install them
onto the frame or fuel tank applying an aclhesive agent

Fuel Tank Cleaning/Inspection

CleM 1M ",In a................. and take are""'~

no 8pIII'k orlame ........... __ the worIcII-a .... - - - GIl ...
dIngar at hlgltlJ .......... _ _ do nat ... ....,..... or low .....
poInIlOIvanIs to . . . . . ....

eRemove the fuel tank and drain it

• Remove the fuelleve! gauge [A] .
• Pour some high flash-point solvent into the fuel tank and shake the
tank to remove dirt and fuel deposits.
• Pour the solvent out-of the tank.
• Dry the tank with compressed air.
eVisual1y inspect the gaskets on the fuel level gauge and fuel tank cap
for .any damage.
*Repiace the gaskets if they are damaged.
 COOLING SYSTEM 3-1

Cooling ,System
Table ,of Contents

Exploded View ...,..""'..........:........ "..... ,.,, ....... :........ "' ........................................................3-2

Specification~ ...... ".........................................."............................ "................... ".... ,...... 3-3
Coolant ........ ,...............................................................................................................3-4
Coolant Level Inspection ................................"...................... "" ................'.. "............3-4
Coo,lant Draining ...................."..................,............................."" ...............................3~4
Coollan! FUlling .......... ",'" .............................'..............................................................3-5
Pressure Testing ..... ".................. '.................... "' .•. "'..... ~ .............................................3-6
Water Pump ..............................".... "............................................."...............................3-7
Water Pump Remova,I ..................................."..........................................................3-7
Water Pump Installation ......"........................................"......................... ".. ".......... ,.. 3-7
Water Pump inspection ...... ,.................. "." ....".........................................,'." ..............3-8
Radiator and Radiator Fan ........................"",, .......................................................".......3-9
Radiator Remoy,al .. "" ...................... "" ...... "' ..................... "' ..............."....... "" .............. ".3-9
Radiator Inspection ................................."..............................................'...............,,,.3-9
Radiator C:leaning .......................... "..................................................... ".............. "".. 3-9
Radiator Cap ......"." ..................... ".......... ".................................. "........ ".......................3-10
Radiator Cap Inspection ........ ".......... "................. "'''' .........'............. '.' .......................3-10
Thermostat ............................................................ "' ... "' ..................... "" .......................3-11
Thermostat Re,moYal ................... "..................... "....."...... ".............. ".......................3-11
Thel1mostat Installation ................".. "." ............... "" ..........................'.......... _............3-11
Therlmostat Inspection ..........................................................'....... ,," .......................3-11
Hoses and Pipes,."." ............ "............. "..... "............ ".. "...........................".......................3-12
Hose and Pipe Installation ...........".. "." .......... "................................".......................3-12
Hose Inspection ...........................".......... '....... "..................... "................................3-12
3-2 COOLING SYSTEM
Exploded View

SS : Apply silicone sealant.

, T1: 8.8 Nom (0.90 kg-m,78 In-Ib)

12: 25N-m (2.5 kg-m, 18.0 ft-Ib)

T1
 COOLING SYSTEM 3-3
Specifications

Item Standard Service Limit

I,
Coolant:
Type Permanent type of antifreeze I - --
(Soft water and ethylene glycol plus corrosion
and, rust inhibitor chemicals for aluminum ,
i
engines and radiators)
i
Color Green - --
i
Mixed ratiio Soft water 50%, coolant 50% - --
Freezing point -36'C {-31'F} ,
,
- --
I
I
Total amount 2.7 L - --
, Radiata,r Cap:
Rel!ief pressure 93 - 123 kPa
(0. ,96 - 1 .26 !kg/cm2 , 14 - 18 psi) - --
Thermostat:
Vallve opening temperature 63 - 67'C (145 - 153°F) I
- --
Va,lve full opening lift 7 mm or more @9O"C (194°F) I
I
- --
Water Pump:
Water pump shaft diameter 9.976 mm - 9.990 rom 9.94mm I
!

Water pump shaft

bearing inside diameter 10.020 - 10.038 mm 10.09 mm

Spacial Tool - BearIng Driver Set 57001 ..1121

Sealant - Kawasaki Bond (SIlIcOne Sealant): 5101.120

Coola!nt !Flow Chart

A. Radiator
B. RadIalDr Cap
C. Reservoir Tank
D. ThermoaIat
E.EngIne
F. Water Pump
3-4 COOLING SYSTEM
Coolant

Coolant Level Inspection

NOTE
o Check the level when the engine is cold (room of ambient temper-
IiIture).

Do nat check Ihe leVel througIIlhe coolllnt fllie' by .........Ing !he

.......-cap. . . . cap Is _ _ llecool8dwm_ outfram!he
. . .rvoIr lank.

.Check the coolant level in the reservoir tank [Al with the vehicle 1!8Id
perpendicularly.
*It the coolant level is lower than the L (Low)[B] mark. remove tha
reservoir tank cap [C). then add coolant to the F (Full) [D) mark.

CAUTION
For refilling, add Ihe spcIIIed mixture aI cool8nl ..... soli - .
AddIng _ _ _ dl....... coolant ..... cIeg. . . . 1 1 1 _
slclt plapet .....
11Ie dIIuIIcI cooIanI COllI - * ... IllumIlUn _ _ perIL In an
emergency. 10ft _ . can be 8dded. But ... dlkdild cooIanI_
be reIumad to ... cornet mIxtUre rIIIIo will'"
• cooIInI _
8'" cIay&
be 8dded allen. or !be . . .rvoIr . . . has run
comp/8IIII)' drr, .... Is ........bIJ ...... In ... cooling .,-n.
Chack 1Ie.,-1or .......

Coolant Draining
.. WARNING
To avoid burna, do nat _ _ lie I'IICIlator cap or by to change lie
cooIanI_ lie eng.... Is stili hal. Wall unIIlll cools _ _ Coolant
on IIras wlH make IIIem slippery ..... can _ an accldant and

eng..... or ._Is.
In/wy. 1m_1y _ _ay any cooIanIlhllllpIIII 011 llelreme.

SInce cooIanIls hIIrmIuI to lie _an -,. do nat _lor d.I_Ing•

• Remove:
Radiator Cap [A] at Reservoir Tank
Radiator Gap [Bl ai Radiator
ORemove the radiator cap in two steps. First tum tile cap counter-
clockwise to the first stop. Then push and tum it further in the same
direction and remove the cap.
• Pull off the reservoir tank hose [el and pour the coolant into a
container.
 COOLING SYSTEM 3·5

• Remove:
Torque Converter
Coolant D,rain Plugs [A] at Cylinders
o Plac'e a container under the drain plugs.

• Remove:
Front Final.1 Gear Case Skid Plate (KAF620A)
Coolant Oira.in Plugs [AJ at Water Pipesi
o Place a container under the draiin plugs.

Coolant Filling
.Tighten the drain plugs.
• Fill the cooling. system up to the coolant filler neck [AJ with coolant

NOTE
o Pour in the coolant slowly so that the air in the engine and radiator
can escape.

Soft or dlslll.ledi water must be ned: with antifreeze (see Speclflca-

lions In this chapler) In the cooling system.
I hard watar Is used In the sy&tem, It causes scale accwnulallon In i

, the waler passages, cansicIerabIy reduclngl!heelftciency 01 the I

I cooling system.

Waler and Coolant Mbdure Rallo (Recommended)

SolI Water 50 %
Coolant 50 %
Freezing Point - arc (- 31"F)
Tolal Amount 1.7 L

NOTE
o Choose a suitable mixture ratio by referring to the coolant
manufacture's directions.
• Bleed the air from the cooling system as follows.
o Sta'rt the ,engine with the radiator cap at the reservoir tank. removed and
run it until no more air bubbles [8] can be seen in the coolant.
o Tap the radiator hoses to force any air bubbles caugiht inside.
o Stop the 'engine and add coolant up to the radiator filler neck.
• ,Install the radiator cap.
• Fill the reservoir tank up to the F (Full) mark with coolant.

I Do ...... _ ..._ _ ~ma ...

3-6 COOLING SYSTEM

Pressure Testing
• Remove the radiator C8,p, and install a cooling system pressure tester
[AJ on the coolant filler neck [B].
NOTE
o Wet the cap sesling sudac. with water Of COO/lnt to prevent
pre8Sureleakage. -
• Build up pressure in the system carefully until the pressure reaches 123
kPa (1.25 kg/cnr, 18 psi).

DurIng ......... 1iIIIIIng, do not .......... ...-n far wIIIch ...

SJ'IIIIm Is....... 1'IIe ........ ~ Is 123 kPa (1.25
1cg1cn12, 18 PII)•

• Watch the gauge for at least 6 seconds.

*If the pressure holds staIdy, 1be system is all right
*If the pl8SiUre drops soon, check for leaks.
 COOLING SYSTEM 3-7
Water Pump

Water Pump Removal

• Remove:
T oirque Converter
Coolant (drain)
Water Hoses [A]
Water Pump Cover [B]

• Remove:
Water Pump Housing [A]

• Remove:
Water Pump Drive Gear [A]
Pin [Bl
Washer [C]
Water Pump ImpeUer [0]
Shaft [E], Pin [F], and O-ring [G]
Mechanical Seal [H]
Oil Seal [I]

Water Pump Installation

.Clean the sliding surface of a new mechanical seal with a high-flash
point solvent and apply a ilittle coolant to thesl.iding surface to give
the mechanical seal initial lubrication .
• Apply coolant to the surfaces of the rubber seal and sealing seat [A].
and press the rubber sea.1 IB] and sealing seat into,the impeller by hand
until the seaIIt bottoms out.

.,Fit the washer tab [A] to the notch [8] of the housing .
• Fit the drive gear notches [e] to the pin [OJ.
3-8 COOLING SYSTEM

.h'lstall the water pump housing tuming the impeller so that the drive
gear [A] engages with the camshaft gear [8] ,.
• Torque:
Torque - Water Pump Cover Bolls: 8.8 N-m (0;90 kg-m, 78 In-Ib)

Water Pump inspection

.Check the drainage outlet passage [AJ at the bottom of the water
pump body for coolant leakage.
*If the mechanical seal is damaged, the coolant leaks through the seal
and drains through the passages Replace the mechanical seal [8] or
O-ring [C] .

• Measure the diameter [AJ of the water pump shaft.

*If the shaft has worn past the service limit, replace the shaft with a new
one.
Walei' Pump, SI1afI Dlameler
S1allldard: 9.175 - 9.910 mm
SeriIce limit 1.14 mm

• Measure the inside diameter [A) of the water pump shaft bearing.
*If the bearing,has wom past the service limit, repl.ace the crankcase
with a new 00'9.

Water Pump Shaft BearIng I1181deDIameter

Standard: 10.ozo - 10.038 mm
Service Ulnlt 10.09 mm
 COOLING SYSTEM 3-9
iRadiator and Radiator Fan

Radiator Removal
AWARNING
The radiator fan is connected dlrec:ttv 10 1M ballery.. 11Ie radialor' fan .
may start even II lie Ignllion switch Is 01. NEVER "TOUCH THE
RADIATOR FAN UrmLTHERADIATOR FAN CONNECTOR IS i
DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR .
IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN
BlADES.

• Remove:
Coolant (drain)
Fl'Ont Fender Upper
Radiator Mounting Bolts [A]
Water Hose Clamps (loosen) [B]
Radiator [C] and Radiator Fan [OJ

I :Do notlouch the radlallar core. This could damage the radlalor .....
. resulting In loss 01 cooIlngl elk:1encJ.

Radiator Inspection
• Check the radiator core.
* If there are obstructions to air flow, lremove them.
*If the corrugated fins [Al are deformed, carefully straighten them.
* If the air passages of the radiator core are block8d Imore than 20 % by
unremovable obstructions or irreparable deformed fins, replace the
radiator with a new one.

Radiator Cleaning

Clean.. radIaIIor screen and the radiator In acconIance will lie

PerIodIc.MaJnIenanCe CharI. .In dully ......, Ihey should be cluned
more frequenIIr Ihan the recommeIKIedlnlerval. AIIIIr riding through
muddy tarra.... the radIaIor acreen and lie racllaIorlhoulid be
cleaned Immedfalely•.

• Remoye:
Front,Fender Front. Cover
Radiator Screen Mounting Bolts [A]
Radiator Screen [B)
.Clean the radiator screen in a bath of tap watel'~ and then dry it with
compressed air or by shaking it.

· When cleaning the radiator wIh steam cleaner, be careCul of the

following to prevent radiator damage.
· 'Keepltle steam gun [C1 away more than 0.5 m [DJ from the nIdIIdDr
· core [E].
. Holdlhe steam gun perpendicular to the core surface.
Run the steam gun toIkMlng the coreftn dlll'ecllOn (F].
3-10 COOLING SYSTEM
Radiator Cap

The radiator cap at the reservoir tank has the pressure relief valve. and
must be inspected. Tne cap at the radi.ator has no valve.

. Do not changelhe posItIonaollle radlalor cap at the I'888I'¥OirIank

and lie cap at lie radlalar.

Radiator Cap Inspection

.Check the radiator cap valve seals [AJ and valve sprin,g [B).
*If anyone of them shows visible damage, replace the ,cap.

• Install the cap fA] on a cooling system pressure tester [8].

NOTE
o Wet the cap sealing surfaces with water Of coolant to prevent
pressure leakage.
• Watching the pressure gauge, slowly pump the pressure tester to build
. up the pressure. The gauge pointer must remain within the relief
pressure range in the table below at least. 6 seconds. Continue to
pump the tester until the relief valve opens. indicated by the gauge
pointer flicks downward. The relief valve must open within the
specified range.

Radlalor cap RetIefP.........

Standard: 93 - 123kPa (0.95 - 1.25 kgJcm2, 14 - 18 psI) for
8second1.
*If the cap cannot hold the specified pressure, or if it holds too much
pressure, replace it. with a new one.
 COOLING SYSTEM 3-11
Thermostat

Thermostat Removal
• Remove:
Coolant (drain)
Thermostat Housing Cap Bolts [A]
Thermostat HOlJsing Cap [8]

Thermostat Installation
• Install the thermostat [A] so that the jiggle valve [8] is 011'1 top.
• Adjust:
Coolant

Thermostat Inspection
.IRemov,e the thermostat,. and inspect the thermostat valve [A] at room
temperature.
*If the valve is open. replace the valve wittla new one.

• To check valve opening temperature, suspend the thermostat in a

container of water and raise the ternpet'atUre of the water.
* If the measurement is out of the specified range, repla.ce the thermo-
stat.
ThennOllat Valve Opening Temperature
Standard: 63 - src (1.45 '" 1S3"F)
OThe thermostat [A] must be complete'Jy submerged alnd must not
touch the container sides or bottom. Suspend an accurate
thermometer ['8] in the water. It must not touch the container, either.
3-12 COOLING SYSTEM
Hoses and Pipes

Hose and Pipe Installation

.Install the hoses and pipes being, careful to follow bending direction
or diameter. Avoid sharp bending, kinking, f'latten'ing, or twisting .
• Install the clamps as near as possible to the hose end to clear the raised
rib or the fitting. This will prevent the hoses from working loose.
o The cl,amp screws should be positioned correctly to prevent the clamps
from contacting anything.

Hose Inspection
.Visuallv inspect the hoses for signs of deterioration. Squeeze the
hoses. A hose should not be hard and brittle, nor should it be soft or
swollen .
• Replace any damaged hoses.,
 ENGINE TOP END 4-1

Engine Top End

Table of Contents

Exploded View ............................................................................................................4· 2

SpecifICations ..............................................................................................................4-3
Cylinder Head ..............................................................................................................4-4
Cylinder Compression Measurement .....................................................................4-4
Cylinder Head Removal ..........................................................................................4-5
Cylinder Head Installation ......................................................................................4-5
Cylinder Head Disassembly and Assembly
(Valve Mechanism Removal and Installation) .....................................................4.6
Cylinder Head Warp................................................................................................4-7
Valves ...........................................................................................................................4.8
Valve Clearance Inspection ....................................................................................4-8
Valve Clearance Adjustment.. .................................................................................4.9
Valve Seat Inspection ...........................................................................................4-1 0
Valve Seat Repair ..................................................................................................4-10
Valve Spring Free Length .....................................................................................4-13
Valve Head Thickness ...........................................................................................4-13
Valve Stem Bend ..................................................................................................4-13
Valve Stem Dia.rneter ........·.. ·.... ·· ..........................................................................4.13
Valve Guide Inside Diameter ................................................................................4.13
Measuring Valve/Guide Clearance (Wobble Method) .......................................4-14
Rocker Arm/Shaft Wear ·.. ·· .......... ·........... ·...........................................................4-14
Rocker Arm Push Rod Inspection ........................................................................4_14
Exhaust Pipe and Muffler .........................................................................................4-15
Exhaust Pipe Removal ..........................................................................................4-15
Muffler Removal ...................................................................................................4-15
Exhaust Pipe and Muffler Installation ..................................................................4.15
Exhaust Pipe and Muffler Inspection ...................................................................4.15
Spark Arrester Cleaning ........... ,............................................................................4-15
4-2 ENGINE TOP END
Exploded VIeW

L : Apply I'IOft1)8nnanent locking agent.

S : Follow speclfledUgNenIng sequence.•

n : 9.8 N-m (1.0 kg-m, 87 in-Ib)

T2: 22 N..m (2.2~, 11.0 ft-Ib)

//
 ENGINE TOP END 4-3
Specifications

Item Standard Service Umit

Cylinder Heads:
Cylinder compression (Usable Range)
1 000 -1 520 kPa (10.2- - --
15.5 kg/~, 145 - 220 psi)
@490 r/min (rpm) I

Cylinder head warp --- 0.03mm

. Valves:
Valve clearance (when cokl)
Valve head thickness
O.25mm - --
O.85mm 0.4mm
Valve stem bend Less than 0.01 mm TIR 0.05mmTlR
Valve stem diameter: Inlet 5.960 - 5.975 mm 5.95mm
Exhaust 5.960 - 5.965 mm 5.94mm
Valve guide inside diameter 6.000 .., 6.015 mm . 6.08mm
Valve spring free length 32.55mm 31.6mm
Valve seating surface:
Width 0.5 -1.1 mm - --
Outside diameter: Inlet 29.5mm - --
Exhaust 25.5mm - --
Valve seat cutting angle 45- - --
Valve/guide clearance (wobble method):
Inlet 0.06 - 0.12 nan 0.23mm·
Exhaust 0.08 - 0.14 mm O.25mm
Rock.erann inside diameter 12.006 - 12:.024 mm 1.2.05mm
Rocker shaft diameter 11.989 ~ 12.000 mm 11.95rnm
Rocker arm push rod runout Less than .0.5 mm llR O.SmmliR
SpacIal Tool - a.tde. CIndIp PIIera: S7W1-144
Valve .... CUIIIr, 45" - CI»35: 57Ut1-1118
VaIN"" CUller," - CII'3O: 57001-1120
VaIw"" CUIiIr ItaIdar Bar: 57OD1-11.
Valve .... QaIIr, 45" - eNG: S7W1-1187
Valve_CUller," - $33: 57Ut1-11.
Valve AdJUIIInI SInw HoIdar: 57OD1-1217
V_ . . . Culler Holder, CII8: 57OItI!-131O
4-4 ENGINE TOP END
Cylinder Head

Cylinder Compression Measurement

.Tilt up the cargo bed.
• Thoroughly warm up the engine so that the engine oil between the
piston and the cylinder wan will help seal compression as it does
during normal running.
eStop the engine, remove .the spal'k plugs, and attach a compression
gaugefinnly into the one spark plug hole.
eUsing the starter motor, tum the engine over with the throttle fu.lly
open until the compression gauge stops rising; this is the highest
compression reading obtainable.
Cytlnder Cclmpreealon
Usable Range: 1 000 - 1 520 kPa
(1G.2 - 15.5Icg1crn2,145 - 228 psi)
@laO rlmln (rpm)
eRepeat the measurement to the other cylinder.

The following table should be consulted if the obtainable compression reading is not within the usable range..
Problem Diagnosis Remedy (Action)
Cylinder compression carbon accumulation on piston and cylinder Remove the carbon deposits and replace
higher than usable range head, a!nd in combustion chamber possibly damaged parts if necessa.ry. ,

due to damaged valve stem oil seal and/or

damaged piston oil rings
Incorrect cylinder head gasket thickness Replace with a gasket of the proper thickness
Cylinder compress,ion Gas leakage around cylinder head Replace damaged gasket and check
lower than usable range cylinder head warp.
Bad condition of valve seating Repair if possible.
Incorrect valve, p.iston/cylinder clearance Adjust.
Piston seizure I
,
Inspect cylinder and liner and replace/
,
repair as necessary.
I ~ad condition of piston ring and/or piston
nog grooves
Replace..
I
 ENGINE TOP END 4-5

Cylinder Head Removal

• Remove:
Cargo Bed
TOlrqueConverter
Coolant (drain)
Water Hoses
Carburetor
Carburetor Intake Manifold [A]
Muffler and Exhaust Pipe
Spark Plug Caps
Cyliinder Head Covers [B]
Alternator Cover [CJ

.Tum'the alternator rotor clockwise so that the mark IrR" [A] on the
rotor aligns with the mark [B] on the crankcase breather cover. Check
the rocker arms are free. ' If not tum the rotor more one tum and free
the rocker anns.

• Remove:
Cylinder Head Bolls [A]
Cvlinder Head [B]
Cylinder Head Gasket
Rocker Arm Push iRods Ie]

Cylinder Head Installation

.Clean the mating surface of the cylinder head and th~ cylinder.
• Repl,ace the gasket with a new one.
• CheCk to see that the cylinder head knock pins [A] are in place on the
cylinder.
4-6 ENGIN,E TOP END

.lnstal'l the rocker ann push rods.

oTum the alternator rotor clockwise so that the mark "R" [A] on the
rotor aUgns with the mark [8] on the crankcase breather cover.

o To instaU the push rod in a correct position on the tappet, insert the
push rod [AJ so that the end of the push rod is sliding down along
inside wall [BJ of the crankcase and posmon the push rod end on to
the tappet [C].
o Check both inlet and emaust push rods on each cylinder are lowest
position [OJ on the cam lobes. If net tum the altemator rotor
clockwise more one tum and align both marks on the rotor and
breather cover again. .
o Be sure the end of the push rods are correctly seated on the tappets.

,.Tlghteri the cylinder head bolts in the order shown.

Torque - Cytlnder Head Bolla : 22 N-m (2.2 tcg.m, 18.5 fI.I:I,)
.Adjust.
Valve Clearance Adjus1meJJt

• Route the electric wires.

 ENGINE TOP END 4-7

Cylinder Head Disassembly and Assembly

(Valve Mechanism Removal and Installation)
• Remove:
Circlips [A]
Rocker Shaft [B]
Rocker Anns [C]
SpeciaJ Tool - 'OUtside ~Pllers: S7OO1·144

• Remow:
Va'Ne Spring RetainelS [A]
Split Keepers [81
Va!lve Springs
Valves
o Press down the valve .spring retainer ho,lding the valve head, and
remow the split keepers.

• Remove:
Oi,l Seals [A]
Spring Seats fB]

• Check to see that the valve moves smoothly up and down in the guide.
• Check to' see that the valve seats property in the valve $eat. If it does
. not.. repair the valve seat
.Apply engine oil:
Valve Stems
Rocker Shaft

Cylinder Head Warp .'

• Lay a straightedge [A] across the lower surface of ~_.1eveIraf
different points, and measure warp by ,inserting a th~gauge (8]
between the stra,ightedge and the head. .
*If warp exceeds thesenrice limit, repair the mating surface... Replace the
cylinder head if the mating surface is badly damaged.
Cylinder HeadiWarp
Servtce Um,It 0.01 nun
4-8 ENGINE TOP END
Valves

Valve Clearance Inspection

NOTE
o Valve clearance must be checked when the engine is cold (at room
temperature) .
• Remove:
Altemator Cover [AJ
Cylinder Head CoWf'S [8]
Spark Plugs

-Turn the alternator rotor clockwise so that the mark "1" [A) or "r
[B) on the rotor alig'lS with the mark [C) on the crankcase breather
cover. Oleck both rocker arms are free. If not, turn the rotor more
one turn and free both rocker arms.
NOTE
o The marie "1".is for the No.1 cyUnder, and "T is.for the No.2 cylinder..

• Using a thickness gauge, measure the valve clealClnce between the

rocker ann and the valve stem.
* If the valve cleara,nce is incolreCt, adjust it.
Valve C1earance (when cold)
Standard: 0.25 mm

Valve Clearance' Adjustment

• Loosen the valve adjusting screw locknut [A] .
• Tum the valve adjusting screw [6] until the correct clealClnce is
obtained .
• Holding the adjusting screw. with the holder [C], tighten the locknut.
Special Tool - Valve AcqusIIng Screw Holder: 57001·1217
lOl'qU8 - I.ocknul: 9.8 N-m (1.0 kg-m. fllln-lb)
 ENGINE TOP END 4-9

Valve Seat Inspection

• Remove the valve.
• Coat the valve seat with machinist's dye.
• Push the valve into the guide.
• Rotate the valve' against the seat with a lapping tool.
• Pull the valve out, and check the seating pattem on the valve head. It
must be the correct width [AJ and even all the way around.
NOTE
o The lIalve stem and guide must be in good condition~ or this check
will.not be valid.
*.Measure
00
If valve seating pattern is not
the repair the seat
correct,
the outside diameter [8] of the seating pattem on the valve
seat
*If the oU1Side diameter of the valve seating pattern is too large or too
small, repair the seat.
Good Too Wide
Valve SeaIIIIg Surface 0IaIde DIameIer

00
Inlet: 29.5mm
ExbauII: 2S.5 nun
Valve SealIng Surface WIdIh
SIancIanI: o.s ... 1.1 nun
Too Narrow Uneven

Valve Seat Repair

• Follow the manufactunlr's instructions for use of valve seat cutters.
SpecIaITooI- Valve_CUller," - . . 57081-1118 [IN]
VaIN_CUller, 32" - CI>3O: 57081-1120 [EX]
Valve Seal CuIIar, 45- - eNG: 57081-1187 ~EX]
Valve Seal a.r, 32" - 41'33: 57081-11. [IN]
Valve Seal CUller Holder, 411: 57081-1_
Valve Seal CUIIar Holder Bar: 57801-1128
*If the manufacture's instructions are not available, use the follOWing
procedure.

Seat Cutter Operating Cares:

1. The valve seat cutter is designed only for valve seat repair. Therefore
the cutter must not be used for other purposes.
2. Do not drop or hit the valve seat cutter, or the diamond particleS
may falloff.
3. Do not fail to apply engine oil to the valve seat cutler before
grinding the seat surface. Also wash off ground partictes sticking
to the cutter with washing oi\.
NOTE
000 not use a wire brush to remove the metal particles from the cuttsr.
It wl11 take off the diamond pat1ic/es.
4. Setting the valve seat cutter holder in position, operate the cutter
with one hand. Do not apply too much force to the diamond
portion.
NOTE
OPr;or to grinding, apply oil to the cutter, and during the operation
wash off any ground particles sticking to the cuttet with washing
oil
5. After use wash the cutter with washing oil and apply a thin laver of
engine oil before storing.
4-10 ENGINE TOP END

Marks Stamped on the Cutter:

The marks stamped on the back. of the cutter represent the following.
60 ................................... Cutter angle (A]
37.5!Jl ........................... Outer diameter of cutter [8]

Operating Procedures:
.Clean the seat area ca:refully.
• Coat the seat with machinist's dye.
• Fit a 45 cutter to the holder and slide it into the v:alve guide.
9

• Press down lightly 011 the handle and tum it ~ight or left. Grind the
seating surface only until it is smooth.

Do noIgrind Ihe seat too rnucb. 0VergrInd/Rg win reduce vtdve

clearance by aIMing"" valve lido the head. If Ihe valve 8""100 far
IntIo Ihe head, It win be Impoaille 110 adjust: the clearance,Md lie
cylinder head rnusI be replaced.

.Measure the outside. diameter (0.0.) of the seatiing surface with a

vernier caliper.
*Ifthe 0.0. of the seating surface is too small, repeat the 45· grind until
the diameter is within the specified range.
*If the 0.0. of the seating surface is too large, make the 32· grind
described below.
• Grind the seat at a 32~ angle until the seat 0.0. is within the specified
.range.
oTo make the 32° grind, fit a 32° cutter to the holder, and slide it into the
va!llve guide.
oTum the holder one tum at a time while pressing down very lightly.
Check the seat after each tum.

The 32° cullar removes material very quickly. Check the .... outside
dlamel8r ~ to preveat overgrladlng.

oAfter making the 32° grind, retum to the seat 0.0. measurrementstep
above.
• Lap the valve to the seat~ once the seat width and 0.0. are within the
rang'es specified above.
o Put a little coarse grinding compound on the face of the valve in a
number of places around the valve head.
o Spin the valve against the seat until the grinding compound produces
al smooth. matched. surface on both the seat and the valve.
o Repeat the process with a tine grinding compound.
• The seating area should be marked about in the middle of the valve
face.
*11 the seat area is not in the right place on the valve, check to be sure
the valve is the correct part. If it is, it. may have been refaced too much;
~Iaceit.
• Se sure to remove all grinding compound before assembly.
• When the ,engine is assembled, be sure to adjust the valve ,clearances
(see Valve Clearance Adjustment).
 ENGINE TOP EN. 0, 4-11

( START )
t
,
,
I
Machinist's
dye on seat

45° Grind
Tool: 4~ Cutter
Purpose: make seating area
'I smooth and rou nd

t
Measure Seating Area 0.0.
..

-
I,
Tool Vernier Caliper
Purpose:. ,check seat 0.0.
against spec.

1T 001
t
small J L
,
Reiu'ts

OK I I
t
Too blig I

Tool:
45° Grind•
4S°Cutter
t
Machinist's
dye on seat
Purpose: increase O. D. ·of seat
area to spec. I t
I 32° Grind
I Tool: 32°Cutter
I
Purpose: reduc,e 0.0. of seat area
I
to spec.
,
t I

Lap Valve
Tools: Valve lapper, grinding
compound
Purpose: perfectly match valve
I
I

,
and seat area; check
valve head for damage

( FINISHED )
4-12 ENGINE lOPENO

Valve Spring Free Length

• Measure the valve spring free length.
*If the free length is less than the service limit, replace the valve spring
with a new one.
Valve Spring Free LengIh
Standard: 32.55 mm
Service Umit 31.6 mm

Valve Head Thickness

• Measure the thickness [A] of the valVe head.
*If the valve head thickness is less than the serv,ice limit, replace the
valve with a new one.
Yal¥e Head ThIclme8s
Standard: 0.85 mm
Service Umtt OA mm

Valve Stem Bend

• Place the valve in V blocks at each end of the stem, and set a dial gauge
01'1 the stem at a point halfway between the blocks. Tum the valve to
measure the bend.. The difference between the highest and the lowest
dial readings is the amount of bend.
* If the valve stem bend is greater than the service limit, replace the valve
with a new one.
Yalve SII8m Bend
Standard: Lela than 0.01 mm TlR
Service LImit 0.05 mm 11R

Valve Stem Diameter

• Measure Ihe diameter [A] of the valve stem in two directions at right
ang':les,at four different posi;lions on the stem.
*If any single measurement is less than the service Hrnit, replace the
va.lve with a new one.
Yalve Stem Diameter
Standard Service limit
Inlet 5.960 - 5.975 mm 5.95mm
Exhaust 5.950 - 5.965 mm 5.14mm

Valve Guide Inside Diameter

• Measure the inside diameter fA) of the valve guide.
* If the valve guide has worn past the service limit replace the cylinder
head.
Valve Guide Inside Diameter
Standard: 6.0lI0 - 1.015 mm
Service LImit 6.08 mm
 ENGINE TOP END 4-13

Measuring Valve/Guide Clearance (Wobble Method)

If a small bore gaug,e is Illot available, inspect the valve guide wear by
measuring the vallve/guide clearance with the wobble method, as
indicated below .
• Insert a new va'lve into the guide from the top of the head .
• Set a dial gauge against the stem perpendiculalr to it as close as
possible to the cylilllder head upper surface.
• Move the stem back. and forth to measure valve/guide clearance.
• Repeat the measullSrTlent in a direction at a right angle to the first.
*If the readingl exceeds the service limit replace the guide.
NOTE
o The r:eading is not actual valve/guide clearance because the
measuling point is above the guide.
Valve/GuIde Clearance (Wobble lIe1hod)
StincIard Servtce limB
Inlet U8-o.12ram G.23ram
EXhaust· 0.08 - 0.14 ram O.25.mm

Rocker Arm/Shaft Wear

'.Measul'8 the diameter [A] of the l'OI::ker shaft.
*If the shaft has worn past the service limit. replace the rocker shah with
a new one.
RocfI:er Shaft. Diameter
Standard: 11;989 - 12.000 mm
Service Limit 11.95 mm

• Measure the inside diameter [Alof the rocker arm.

*If the bearing has worn past the service limit replace the rocker ann
with a new one.
RocfI:er Arm Inside Diameter
Standard: 12.006 -12.024 mm
Service LImit 12.06 mm

Rocker Arm Push Rod Inspection

• Place the rocker arm push rod in V blocks that are as far apart as
possible, and set a dial gauge on the rod at a point halfway between
the blocks. Tum the rod to measure the runout. The difference
between the highest and the lowest dial readings is the amount of
runout
*If the runout exceeds the servioe limit replace the ;rod.
'Rocker Ann ~P1IISh IRod Runoul
Slandard: Less Iban 0.5 mm nR.
Service Umlt. 0.8 mmnR
4-14 ENGINE TOP END
Exhaust P"ipe and Muffler

Exhaust Pipe Removal

• Remove:
Cargo Bed
Mliffle.r
Exhaust Pi.pe Holder Nuts [AJ
Exhaust Pipe [B]

Muffler Removal
• Remove:
Cargo Bed
Clamp Bolt (loosen) [A]
Muffler Mounting ,Bolts [8]
Muffler [C]

Exhaust Pipe and Muffler Installatit:Jn

.Apply non-permanent locking agent
Muffler Mounting 'Bolts
.Check the exhaust. gasket and the muffler connecting gask$: for signs
of damage. If necessary, replace them with new ones.
• After installation, thoroughly warm up the engine, wait until the engine
cools down, and then retighten the clamp bolt and holder nuts.

Exhaust Pipe and Muffler Inspection

• Before removing, check for .signs of leakage at the exhaust pipe gasket
in the cylinder head and at the muffler clamp.
*beIf there are signs of leakage around the exhaust pipe gasket. it should
replaced. I'f the muffler-to-exhaust pipe joint leaks, tighten the
clamp.
• Check the exhaust pipe and muffler for dents. cracks. rust and holes.
* If the exhaust pipe or muffler is damaged, it should be replaced for best
performance and least noise.
 ENGINE TOP END 4-15

Spark Mester Cleaning

ili.WARNIING
. To avoid burns, wear gloves while cleaning the spark arrester. Since
Ihe engine must be run during this procedure, the muRler will .
become hoi.

eRemove the drain .plug [A] from the muffler [8].

eApplv the parking brake,
eln an open area away from combustible materials, start the engine with
the gear shift 'lever in the N(neutral} position.
e Raise and lower engine speed while tapping on the muffler with a
rubber mallet until the carbon particles are purged from the muffler.

.u.WAmJING
Do not lUll Ihe engine Ina cIoIed area. EXhaust gaes contain
C8ItJan mano.xJdej a coIorI•••• odorIeea, poisonous. gas. 8realh1ng
. . . . . gas can lead 10 carbon rnonoJdde poiIonIng, asphyxtaUoR,
and .....

estop the engine.

elinstall the drain plug.
 CONVERTER SYSTEM 5-1

-Converter System
Table of Contents

Exploded View ......................................................"' ....................................................6-2

Specifications .............................., ....... "''''........................................................................6-4.
Torque Convertar............................................................................................................6-6
Torque Convenar Removal ........................................~..............................................6-6
Torque Conwrser Installation .................................................................................6-6
Drive Belt .......................................................................... ~...............................................6-7
Drive Belt Inspection ...............................................................................................6-7
Drive Pulley ....................................................................................................................6-8
Drive Pulley D~.........................................................................................6-8
Drive Pulley Assembly·..:...................................................................~ ......................6-8
Drive PU,IIey Inspection .•·....................................................................................~ ••••6-9,
Driven Pulley ..............................................................................................................6-1·1-
Driven Pu'ley Disassembly ..............................................................~......................5-11
Driven Pulley Assembly ............................................................................................5-12.
Driven Pulley Inspection ........................................................................................6-13
5-2 CONVERTER SYSTEM·
Exploded View

L : Apply non-pennanent locking agent.

M: Applymolybdenumdlsulffde grease•.

T1:1.5 N-m (0.15 kg-m, 131n-lb)

T2: 13 N-m (1.3 kg-m,1131n-1b)
T3 : 93 N-m (9.5 kg-m, 69 ft-Ib)
=======~;;;;;~~~~CO~N~V~E=RT=E=R=S=Y=S=TE=M~
5-3

~D
@
5-4 CONVERTER SYSTEM
Specifications

Item Standard Service Umit

Drive Belt:
Belt width 31.2mm 29mm
Drive Pulley:
Spring free length 69.5mm 66mm
Cover bushing inside diameter 39.984 .... 40.108 mm 4O.14mm
Sheave bushing inside diameter 42.990· - 43.085 mm 43.12 mm
Driven Pulley:
Spring free length 140mm 133mm
Wear shoe ·width - -- 11 mm
Fixed sheave bushing inside diameter 50.075 .... 50.165 mm 5O.20mm
Shaft bushing inside diameter. Small 25.000 .... 25.090 mm 25.13mm
Large 32.013- 32.103 mm 32.14mm

SpecIal Tool - 0uII1de CIn:IIp PlIen: 57.1-144.

Clulch Holder: 57OD1-1.
,.,..... HOlder: 5700'1-1313
 CONVERTER SYSTEM 5~5

Torque Converter

Torque Converter Removal

• Remove:
Cargo Bed
Air Ducts [A]
TOl'Clue Converter Cover [8]

• Remove:
Coolingl Fan andCovet' [A}

.Using the clutch holder [AJ, remove the drive pulley bolt [8]..

Be sure to ...... cII*h. holder on the drIVe puller cover. • . .

.! bolder Is ... on 1M' spider 1111881nb1y, 1be8888lllbly may be brGIcen.

Special 1001 - Ckdch· Holder: 57001-1243

.Using the flywheel holder [AJ, remove the driven pulley bolt [8].
SpecIal Tool - Flywheel Holder: 57001-1'313

• Remove:
Drive Pulley,. Driven .Pulley, and Drive 8elt
Spacer [A]
Converter Case [8J
5-6 CONVERTER SYSTEM '

Torque Converter Installation

.Install the spacer [AJ so as to face the chamfered side [B] to the
crankcase.

• Install the drive pulley [AJ, driven pulley [BJ, and drive belt [C]
together.

NOTE
OFirst engage th.splin. on the diiven pulley with the spline on the
drive shaft. next engage the spline on the drive pulley with the spine
on the crankshlllt. and push inm them tDgfIther lit the same time.
o When engaging the spline on the pullflys with the spline on the
shaft£ do not bu" on the pulley's spline. If 1liiY bu" occur. surely
IefTIOIIe it with II file.

• Install the stepped collar [A] and washels [8] as shown on the drive
pulley bolt

.Apply non-permanent locking agent

Driven Pully Bolt
.Torque:
Torque - DrIve Pulley Bolt 93 Nom (I.5Icgo1n..IWb)
Ditven Pulley Bolt 13 N-m (8.5 ........ ft.Ib)
COnveItIr Cower BollI: 1.5 ..... (0.15 kg-m, 13 In-Ib)
SpecIal Tool - Clutch Holder: 57OD1-1.
FlywMaI Holder: 57. .1-1313

• Be sure 10 . . . . . clulch holder on . . drive pulleycover~ . . .

holder Is ... on . . Spider -embIJ... U88lllbly may be braIcen~
 CONVERTER SYSTEM 5-7
Drive Belt

Drive Belt Inspection

• Measure the width of.the belt [A].
*If any measurements exceed the service limit, replace the belt

BeftWIdIh
Standard: 31.2 mm

=.-,--.
~
Service LImit 21 mm
.Chedk the belt for wear, cracks or breaks.
*If necessary, replace the belt with a new one.
Belt [AJ -------
Crack [B]
Kevlar Cord [Cl
Broken [0]

NOTE
o Whenever the belt is replaced, inspect the drive and the driven
pulleys.
5-8 CONVERTER SYSTEM
Drive Pulley

Drive Pulley Disassembly

• Remove:
Cover [A]

• Remove:
Spring [A]
Sleeve [8]
Wear Guides [C]
Spider Assembly.[O]

• Remove:
Split Ring [A]
Movable Sheave [8]
Fixed Sheave

Drive Pulley Assembly

.Align the arrows [A] on the spider assembly [8] and the movable
sheave [C] .

• Fit the wear guides [A] into the correct position between the spider
assembly [8] and the movable sheave [C].
 CONVERTER SYSTEM 5-9

.Put the sleeve [A] on the shaft so that the flanged side [8] is down .

• Align the arrows [A] on the cover [8] and the spider assembly [e)..
• Torque:
Torque - Drive Pulley Coverflolls: 13 Nom (1.3 kg-m.• 1131n-1b)

Drive Pulley Inspection

*If the sheave surfaces [A] . appear damaged, replace the sheaves.

*It the guide bushings [AJ are damaged or wom, replace them.
Cover BushIng inside DI8meIer
Standard: 39.984 - 40.108 mml
Service limit 40.14 mm
Sheave BuaIIIng inside DIameter
Standard: 42.890 - 43.085mm
Service limit 43.12 mm

*If the splines [AJ are badl,y wom, replace the fixed sheave.
5-10 CONVERTER SYSTEM

*If the wear guides [AJ are damaged or worn, replace them.

*Iftheweights [A] are damaged 'OI"wom, replace them.

*If the .pivot pillS [81 are damaged or wom, replace them.
*If the washers [Cl, are damaged or worn. replace them.

*If the rollers [A] are damaged or wom, replace them.

*If the pins [8] a,re damaged orwom.replace them.
*If the washers [Cl are damaged or worn. replace them.

*If the spring free length [A] is shortel than the service limit. replace the
spring.

SprIng Free LengIIl

Standard: 69.5 mm
ServIce Unit 66 mm
 CONVERTER SYSTEM 5-11
Driven Pulley

Driven Pulley Disassembly

• Make the driven .pullev holder as shown if necessary.
A. Wooden Board: 500 x 500 x 10 mm
B. Radius: 80 mm
C. Bolts: 6 mm dia., 30 mm length
D. Stopper Pin: 8 mm dia.• 25 mm length
:e. Wiw. 140mm _gtb
F.130mm
G.150mm

• Remove:
Coupling fA]

NOTE
o Do not loosen tile coupling itI$ift bolts [8]. The shaft hub [C] and
the co'upler ptars [0] are bBkmced at the factory.

• Disassemble the driven pulley in accordance with the following

procedures.
1. Set the driven pul.ley on the driven pulley holder.
2. Tum the fixed sheave [AJ counterclockwise about 45°.
3. Hold the fixed sheave with the stopper pin [8].
4. Press the ramp cap Ie].
5. Remow the ciroli.p [OJ.
6. Release the fixed sheave slowly.
7. Remove the ramp cap and spring.
Special loot - 0uIs1de CIrcIIp PlIers: 57001-144

o Mark and record the locations of the spring end fitting holes [Al.
5-12 CONVER.TER SYSTEM

Driven Pulley Assembly

elnstall the spring onto the fixed sheave [A], ,inserting the spring end
into the hole "'8" [8].

eput the ramp cap [A] on the spring. inserting the spring end into the
hole "2" [8].

ePressthe ramp cap [A] onto the movable sheave shaft ['B}, aligning
the arrow on the ramp cap with the punch mark on the shaft tel.

eTum the fixed sheave [A]countercliockwise whiile pressing the nmp

cap [B]until the arrow [Clan the sheave passes over the anow [0]
on the cap.
• Hold the fixed sheave with the stopper pin [El·

.install the new cirelip [A] while pressing the ramp cap [BJ to the
bottom.
Special Tool - OUIIkIe CIrcIIp PlIen: 57001-144

NOTE
Olnstall the circlip so that the opening [C] is aligned with a spline
groove (D].
 CONVERTER SYSTEM 5-13

• Check for the alignment of the arrows [A] on the fixed sheave [8] and
the ramp cap [C] .

• Instan the oouplil119 rAJ· so that the arrow [B] on it is aligned with the
arrow [81 on the fixed sheave [C] .
• Torque:
Torque - DrIven Pulley Coupling Bolts: 13 Nom (1.3 kg-m, 113 In-Ib)

.Driven Pulley Inspection

*If the sheave SllJrfaces [A] appear damaged, replace the sheaves.
*rt the guide bushinQ$ (Blare damaged o,r worn, replace them.
fixed Sheave Bustling ..... Diam...'
Standard: 5G.075 - 50.115 mm
Service Umlt 50.20 mm
Shaft Bushing inside DIameI8r (Small)
Standard: 25.000 - 2SJJ8O mm
Service LImit 25.13 mm
ShaftBuahIng inside DIameIer (Larga)
Standard: 32.013- 32.103 mm
Service LImit 32.14 mm

*If the splines tA] are damaged or worn, replace them.

5-14 CONVERTER SYSTEM

*If the iramps [A]o,r the wear shoes [8] are damaged or worn, replace
the .ramp cap [C] or the shoes.

*If the wear shoe contact area width ![A] is greater than the service limit,
replace the shoe [9].

Wear Shoe WIdIh

Service Ulnl: 11 mm

*If the spring free length [A] is shorter than the service limit. replace the
spring.
SprIng Free LengIIt
Siandard: 140 mm
ServIce Um'1t 1.33 mm
 'ENGINE LUBRICATION SYSTEM 6,-1

Engi'ne Lubrication System

Table 01 Contents

Exploded View ..................................................................."' ..,.....................................6·2

Specificatiions ." ..............'..................".................."........................................................6-3
Engine Oil ,and Oil Filter ................................................"."." .........................................6-4
Oil Level Inspection ....................."................ "' ......................... "' ....... "' ....................6-4
Oil and/or Filter Change ................"......."...........................................................,." ...6-5
Oil Filrer Removal .............................................."................."..................................6-5
Oil Fiirer ~Installation ......................................."................................".......................6-5
Oil Pump and ReUef Valve ................................ "' .............,........ "' ............. "...................6·,6
Oil Pump and Relief Valve Removal ..... "' ..............,........ ,................... ".....".............".6·,6
Oil Pump and Relief Valve Installation .......'.............. '......,............. '.........................'...6-6
Oil Pump and Relief Valve Inspection .........................,...................,........................6-6
Oil Screen ....................................................... ".............."...... :............ ".........................6-8
Oil Screen Removal .. ".......... "' ............................................................"....................6-8
Oil Screen Installation .......................................,............. "." ......."........... "' ................".6-8
Oil Screen Cleaning/Inspection ..................... "' .... "'........'............... "......................".6-8
6-2 ENGINE LUBRICATION SYSTEM
Exploded View

G: Apply grease.
L. : Apply non-permaneld locking agent.
SS : Apply silicone sealant

n: 22 N-m (2.2kg-m, 16.0 ft-Ib)

12: 25 N-m (2.5 kg-m, 18.8 ft-Ib)

A.... _ ~~
~ - ~
~

G
 ENGINE LUBRICATION SYSTEM 6-3
Specifications

Item Sta,ndard Service Limit

Engine Oil and Oill Filter:
Engine oil: Grade SE, SF, or SG class - --
Viscosity SA.E.10W-4O, 1OW-50, 20W-40, or 20W·5Q - --
Capacity 1 .5 L (when fi·llter is not removed) - --
1.8 L (when filter is removed) - --
Oil level Between upper and lower level lines - -,-
,
• Oil Pump and Retief Valve:
Inner rotor/outer rotor clearance Less than 0.14 mm 0.3mm
Inner rotor shaft diameter 10.973 "'" 10.984 mm i 10.93mm
Inner rotor shaft bearing
inside diameter 11.000 '"' 11 .011 mm 11.07 mm ,
Outer rotor diameter 40 . 53 "'" 40'.56 mm 40.47 mm ,

Outer rotor housing

inside diameter 40.680 '"' 40.701 mm 4O.80mm
Outer rotor width 9.98 "'" 10.00 mm 9 ..83mm
i
Rotor housing depth 10.030 "'" 10.080 mm 10.23mm

Special Tool - 011 Filter Wrenclt 57001-1248

Seelanl - Kawuakl Bond (SlIcane Sealant): . . . . .120

, Engine Oil Flow Chart

6-4 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter

~4.WARNING

Yehlcle operation w.. IneuIIIcIent, delarloralad, or conIamlnated

engine 00 wUl cause accelerated wear and may resui In engine
seizure, accldenl, and Inl..".

Oil Level Inspection

NOTE
o If the vehicle has just been used, wait sevetal minlas for all the oil
to drain down.
Olfthe oil has just been changed, statt the engine and mn it for stMIfBl
minutss at idle speed. This fills the oil fi/tIJI with oil. Stop the engine.
then wait.several minutes until the oil sf1ltles.

I =.......-...=-r,.... .-.. . I
• Park the vehicle on level ground, and tilt up the cargo bed .
• Pull up the dipstick [A] out of the dipstick tube, wipe it dry, and insert
it into the tube securely.
• Pull out the dipstick and check the oil level. The oil level should be
between the upper (H) and lower (l) level lines [B].
*If the oil level is too high. remove the excess oil. using a syringe or
some other suitable device, through the oil filler £C] opening.
*If the oUlevelis too low, add the correct amount of oil through the oil
filler [C] opening. Use the same type and make of oil that is already
in the engine.

NOTE
Olf the engine oil type and malee are·unknown, use any brand of the
specified oil to .top up the level in preference to mnning the engine
with the ai/level/ow. Then atyout earliest convenience, change the
oil complets/y.
 ENGINE LUBRICATIOiN SYSTEM 6-5

Oil and/or Filter Change

.Warm up, the ef1gine so that the oil will pick up any secjimef1t and drain
easily.
• Place an oil pan beneath the engine.
• Remove the engine oil dralin plugs [A], and let the oil drain complete'l/y.
• If the oH filter is to be changed, replace it with a new one.
• Check the gaskets at the drain plugs for damage.
* R.eplace the gaskets with Inew ones if they are damaged.
• After the oil has completely drained out. install the drain plugs with the
gaskets.
Torque - Enght on Drain Pfag (14mm): 22 N-m. (2.2 kg-m, 1&.0 I-Ib)
(1&mm): 25 N-m (2.5 kg-m, 18.0 ft.Ib)
• Fill the engine with a good qua.lity motor oil as specified in the table.
• Check the oil level.
engine 01
Grade: SE. SF. or SO class
VIIIcoaIty: SAE1'OW-40\ 1OW.ao. 2OW-4O, or 28W-50
CapaCity: 1.5 L (when liar Is not removed)
1.1 L (when liar Is I'8IIIOVIICIt
Between upper_lower 1anI1__

Oil Filter Removal

.Tilt up the cargo bed.
• Remove the oil filter [Al.
o When unscrewing the oil filter, cover the filter bottom with a dean
cloth so as not to spill the engine oil out of the filter. Any spilt oli!1
shouldbe wiped up completely.

o Use the oil filter wrench [A] if the oil filter is tight
Specfaj Tool - 011 FIller Wrench: 578.tl-1249

Oil FiltBllnstallation
• Grease:
Oil Filter Gasket
.Install the new filter..
o Screw the fi!lter in until tne gasket toucnes the engine, tnen tum it 3/4
tum .
• Addthe engine oil (see Oil Level Inspection) .
• Thoroug.hly warm up the engine, and check the oi/leakage and the oil
level.
*If necessary, add more engine oil.
6-6 iENIGINE ilUBRIC.ATION 'SYSTEM
on Pump and Relief Valve
Oil Pump and Relief Valve Removal
• 'Remove:
Engine
Crankcase Cover
Oil Pump CoVei' Bohs [A]
Oil Pump Gear [B) and Oil Pump Cover [C]
Oil Pump Inner Rotor [D]
Oil Pump Outer Rotor [E]
Rejief Valve Spring [F]
Steel Ball [G]

100 ... _..,_ .. _=_. _. . _

Oil Pump and Relief Valve Installation

• Install the pump shaft with its pin [A] in the inner rotor slot [B] .
• 'nstall the oil pump' cover [C] so that the cover stops the reHef valve
spring [0] .
• Fill the oil pump with engine oil for initial lubrication.

Oil Pump and Relief Valve Inspection

.Visually inspect the oil pump gear, shaft, ,inner rotor, outer rotor, and
rotor housing [A] in the crankcase.
*If there is any damage or uneven wear, replace them .
• Visually inspect the relief valve spring [B}, and steel ball [e].
*If alny rough spots are found during the above inspection, wash the
valveelean with a high flash-point solvent and blow out any foreign
particles that may be in the valve with compressed air.

.... WARNING
, Clean Ihe ,parts In a wel-venlllaled area, and take care Ihat ..... Is
no spark or flame anywhere near the working area., Becau8eof Ihe
danger of highly fIammab.1e liquids, do not use gasoline or low '
IIash-polni solvents.

*It cleaning does not solve the problem,. replace the relief valVe parts.
 ENGINE LUBRICATION SYSTEM 6-7

• Measure the clearance between the high point of the inner rotor and
the high point of the outer rotor.
* If the clearancee)llceeds the serVice limit, replace the inner and outer
rotors as a set.

Inner RoIDr/Oullr RoIIarC~ .

Sta..dlll'd: ..... than 0.14 mm
Service Uma: 0.3 mm

• Measure the following diameters and width of the oil (lUmp parIS.
*If the p8rt(s) has wom ,past the service limit,. replace the wom part(s).

Inner RoIIor Shalt Diameler

StaIIdarcI: 1o..m ,., 1U84mm
SenIce Umlt 18.13 mm
Inner RGIDr Shalt BearIng InIIcIe DIametar
SIrand8rd: 11.000 -11.cn1 mm
Ser¥Ice Lfmtt11.111 111m
0UIar RoIor Dlameler
Standard: 41.53 ,., 4O.sa mm
Ser¥Ice limit 4OA7 mm
Outler RoIor Housing_ide !DIarneIer
Sl:arKlard:40.8IO - 40.701 nun
Service LImit 40.8Q mm
0uIIer RoIor WlcIh
StandarcI: 9.88 - 10.08 nun
Service Um,1t 9.83 mm
Rotci' Housing DepIh
StaMard: 10.030 - 10.oao mm
hrvlce LImit 10.23 mm,
6-8 ENGINE LUBRICATION SYSTEM
Oil Screen
Oil Screen Remov:al
• Remove:
Engine
Crankcase Cover
Oil Screen Cover Screws [AJ
Oil Screen Cover [BJ
Oil Screen [C]

Oil Screen Installation

• Clean the oil screen thoroughly whenever it is removed.

Oil Screen Cleaning/fnspection

.Clean the oil screen with hig,h flash-point solvent and remow any
particles stuck to it

i .. WARNING
Clean the screen In a welkentilatBdl ...... and lake care that Ihere
Is no spark or tJame anywhere nearlhewortlng area. Because ollie
danger of highly ftammable liquids, do not use gasoline or lOw
ftash-poInt solvents.

NOTE
o While cleaning the screen, check for any metIJl particles that might
indicate internal engine damage.
• Cheek the screen carefully for any damage: holes and broken wire.
*It the screen is damaged, replace it.
 ENGINE REMOVAL I INSTALLATION 7·'

Engine Removal/Installation
Table of ContentS

Exploded View •.•....,................•.•.••.••.••...•...••.............••..., .......•...•....•.•....•...................•.7-2

Specifications ................................................................................................................7-3
Engine Removal/Installation .........................................................................................7-4 .r-:;--)
Engine Removal ......................................! .................... • ..........................................7-4
Engine Installation ..................................................................................................7-5
L.!J
7·2 ENGINE REMOVAL I INSTALLATION
Exploded VIeW
 ENGliNE REMOVAL / INSTA'LLATI'ON 7-3
Specifications
Special Tool - Assembly Jig: 57001-1365
7-4 ENGINE REMOVAL I INSTALLATION
Engine Removal/lnstallation

Engine Removal
• Disconnect:
Battery + Terminal Leads
• Remove:
Engine Oil (drain)
Coolant (drain)
Cargo Bed
Exhaust Pipe and Muffler
Torqu.e Converter
Water Hoses
AjrDuCit
Choke Cable Lower End
Fuel Hose
Cable Bracket Mounting Bolts (2) [A] and Collars

• Disconnect:
Battery Ground Lead [A]
Starter Motor Terminal leads
COl1nectolS (B] from the engine

• RemolJ8:
!Engine Mounting Bolts [AJ
Engine
 ENGINE REMOVAl. / I NSTAl.l.ATIONi 7-5

Engine Installation
.Adjust the engin"e mounting position for alignment of the torque
converter.
o Mount the engine and install the engine mounting bolts loosely.
o Install the assembly jig [AJ onto the transmission drive shaft and
crankshaft.
SpecIal Tool - Assembly J~. 57001-1_
o First fit the assembly jig firmly to the transmission case with tightening
the bolt [8], and then tighten the bolt [C] until the assembly jig is
fitted to the engine completely.

NOTE
o Use the converter case bolt [8] to the transmission case and the
driven pulley bolt [C] and the stepped collar [D] of the drive pulley.
OTighten the engine mounting bohs securely.
o Remove the assembly jig.
OTightei'l the cable bracket mounting bohs securely.
• Adjust
Choke Cable Free Play Adjustment
Engine Oil
Coolant
 ENGINE BOTT'OM END 8-1

Engine BoHom End

Table of Colntents

Exploded View ............... "........ ,....... "...".........................................'...............................8-2

Specificati'ons ...........................'.............,,"' .............................................................".....,8,-3
Crankcase Cover ......................."... ".. ".....,............................................. "........................8-4
Crankcase Cover Removal ..."........ "'''' ...... ''' ..............................................................8-4
CRlnkcase Cover Installation ...... ".....".....................................................................8-4
Camshaft and Tappets ............................................."................"................... ".............'8-5
Camshaft Removal ............................"' .......................................................,.............8-5
Camshaft Installation ..............................................................................................8- 5
Camshaft inspection ...............................................................................................8-5
Cam Wear ......................................................................,..........................................8-5
Ca,mshaft Bearing:/Joum:al Wea,r ......."...."...............................................................8-5
Cylinders and Pistons..................................................................................................8-7
Piston Removal ...,...........".........."......... ,." .."." ........,.....................................................8-7
Piston Installation ................................".. "' ....... "............. ".. ~ ............................,.........8-8
Piston Ring. Piston Ring Groove Wear ..................................................................8-9 "
Piston Ring End Gap ....... "......................................................"...............................8-9
Cyilinder Inside Diiameter .......... "............ "..............................................................8-10
P"iston Diameter ....... '" ..... "....... ".... "..................... "............... """' ..... '., ........................ ".8-10
Boring, Honing ... ".......... "............... ".... "..... ". "........... "................................".......,... ,.. 8-"0
Crankshaft and Connecting Rods '............... "."" ........... "." ..................................... ".....8-11
Connec,ting Rod Removal .. "........................................."........ ".' .............................8-11
Connecting Rod Installation ....."......................... "" ..... ""., .................. ,,,."" ............ ".....8-1 "
CRlnkshaft Remova,I .... "........'.................................'."' ........................................"....8-11
Crankshaft Installation ........ "......................................."...................................."....8-11
Crankshaft Cleaning ........... ".........................................".................................."....8-11
Connecting Rod BendlTwist ............. "" .......".......'...............................................".8-12
Connecting Rod Big End Side Clearance ..............................................................8-12
Connecting Rod Big End Bearing/Crankpin Wear .................................................8-13
Crankshaft Runout ... ", ..............................".........."...................... "................... ".... ",.8-14
Crankshaft Main Bea'ring/Joumal Wear ................................".............................8-14
Breather Valve ....".............'....... '............................'..... ".............."......... '.. ".....................8-15
Brea:ther Valve Removal ..... "..................................................."... ".............. "..........8-15
Breather Valve Installation .. "................................"..... "..........,......................,..........8-15
Brea.ther Valve' Inspecti,on .. ".' .......................... "......................................................8-15
8-2 ENGINE 80
Exploded View TTOM END.

G: AppIyg
L' . rease•
• Apply non-permanent locking agent.

n: 21 N-m.(2.1
12: 22 N-In (2.2 kg-m, 15.0."a,)
kg-m, 1••0 ft-Ib)
 ENGINE BOTTOM END 8-3
Specifications

Item Standard Service Limit

Camshaft and Tappets:
Cam height Inlet 25.719 "" 25.809 mm 25.62 mm
I
I Exhaust 25.962 .... 26.052. mm 25.86 mm
I
Camshaftjoumal diameter 15.957 .... 15.975 mm 15.93 mm
Camshaft bea.ringinside diameter I 16.000 .... 16.018 mm 16.08 mm
Cylinders and Pistons:
IPiston ring/groove clearance: Top 0.04 .... 0.08 mm 0.18mm
Second 0:03 .... 0.07 mm 0.17 mm
Piston ring groove width: Top 1.23 -1.25 mm 1 . 33 mm
I Second 1.22 .... 1.24 mm 1.32 mm
Oil 3.01 .... 3.03· mm 3.11 mm
i Piston ring thickness: Top, Second 1..17 ... 1.19 mm 1.1 mm
Piston ring end gap: Top, Second 0.2 .... 0.4mm O.7mm
Cylinder inside diametel!' 75.980 - 76.000 mm 76.1iOmm
Piston diameter 75.935 - 75.950 mm 75.80mm
Piiston/cylinder clearance 0,030 - 0.065 mm - --
Oversize piston and rings +O.50mm - --
Crankshaft and Connecting Rods:
Connecting rod bend 0.061100mm 0 ..2/100 mm
Connectinlg rod twist 0.06/100 'mm 0 •.2/100 mm
Connecting rod big end side clearance 0.3 -1.1 mm 1.3mm
Connecting· rod big end
bearing/crankpin clearance 0.0.24 - 0.048 mm 0.08mm
I

I
Crankpin diameter 33.967 - 33.980 mm 33.95mm
Connecting! rod big end bearing inside diameter 34.004 ... 34.015 mm 34.05mm
Crankshaft run out Less than 0.02 mm fiR 0.05 mm TIR
Crankshaft main journal diameter 33.959 -33.975 mm 33.94mm
Crankshaft ma~n bearing
inside diameter: on Crankcase 33.997 - 34·.064mm 34.12 mm
(Bushing)
on Crankcase 34.025 - 34.041 mm 34.10 mm
cover

SpecIal Tao! - Piston Ring Pliers: S7OO1~115

PIaIan PIn Puller Aallmbly: 57001-818
PlalanRIng ConIprIllor GrIp: 57001·1_
PIston Ring ConIpreslor Bel, cM1 ... 4179: 57001-1897
8earfng DrlnrSet 57001-11.29
8-4 E,NGINE BOTTOM END
Crankcase Cove.r

Crankcase Cover Removal

• Remove:
Engine
Water Pump
Clankcase Cover Bolts [AJ
Crankcase Cover [B]
NOTE
o If the crankcase cover sticks,. tap lightly with a mallet on the
alternator side near the knock pins.

Crankcase Cover Installation

.Be sure to replace the oil seal removed with a new one. P·ressin the
new oil seal using a press and suitable tools so that the sea'l surface is
flush with the surface of the crankcase cover.
• Check to see that the crankcase knock. pins [A] and O-rings [8J are
in place on the crankcase. If any of them has been removed, replace
it with a new one.

• Apply engine oil:

Crankshaft
Camshaft
• Grease:
Oil Seal lips
.Install the crankcase cover so that the oU pump gear [A] is engaged
with the crankshaft gear.
• Torque:
Torque - Crankcase Cover Bolts :22 N-m (2.2. kg-m, 16.0 N:t)

•. Apply non-permanent· locking agent:

Engine Oil Dipstick Tube Lower End LA]
.Check to see the crankshaft turns freely.
 ENGINE BOTTO'M END 8-5
Camshaft and Ta!ppets

Camshaft Removal
.IRemove:
Engine
Cylinder Heads
Crankcase Cover
Camshaft [A]
Tappets [8]
OTum the engine upside down to keep 1!he tappets from catching the
cam lobes.

Camshaft Installation
.,Applv engine oil:
Tappets
Camshaft Journals
Cam Surtaces
.Align the timing marks [A] on the camshaft and crankshaft. gears.

Camshaft Inspection
• Check the camshaft gear [A] for worn or broken teeU\.
*If excessively wom or broken teeth are observed" replace the camsm.tt

Cam Wear
• Measure the cam height [AJ of each cam.
*If any cam has worn past the service limit replace the camshaft.

C8mHeIgbt
Standard ServlceUml
Inlet 25.719 ... 25.809 nun 25.12mm
ExI1aca 25.962 ... 2I.052mm 25.8&mm

Camshaft Bearing/Journal Wear

• Measure the diameter [AJ of the camshaft journals.
*If any journal ihas worn past1the servi,ce limit. replace the camshaft with
a new one.
camshaft Journal DIameter
Standard: 15.957 ... 15.975 mm
Service Umlt 15J13 mm,
8-6 ENGINE BOTTOM END·

.Measure the inside diameter [A] of the camshaft bearings.

*If any bearing has worn past the service limit, replace the crankcase
and/or crankcase cover with a new one.
camshaft Beartng inside DIameter
Standard: 16.000 - 16.018 mm
Service UnlIt 18.08 mm
 ENGINE BOTTOM END 8-7
eyUnders and Pist.ons

Piston Removal
,.Remove:
Engine
Cylinder Heads
Crankcase Cover
Camsbaft
.Tum the orankshaft to expose the two connecting rod big end cap
bolts.
• Remove:
Connecting Aod Big End Cap Bolts [A]
Connecting Rod Big End Caps [8]

eplJSh the connecting rod ends into the cylinders, and pull the pistons
and connecting rods out of the cylilnd8!'S- '

Nola a 1acaIIan, of lie arrow on . . tap of . . pIaIan In relation 10

appoe:le ,at No.2 pIaIan. Keep padI tIDgIIIar as 8...

MADE IN .:IAPAN .. 1M CGII.1IIICIIng rocLNo.1 CJInder pIllaR II !I
I
A Arrow c. Large Chamfer
8. Alternator D. Raised letter (MADE IN J.APAN)

• Remove ,one Of the piston pin snap rings [A] with needle nose pfiers.

• Remove the piston by pushing the piston pinout tile side from which
the snap ning was removed. Use the piston pin puller assembly [A]
and adaptef "c" [8] if the pin ,is tight
Special Tool - PIsIon PIn Puller Assembly: 57001-910

.Remove the top and second rings with piston iring pliers [A]. If the
special tool is not available, carefully spread the ring opening with your
thumbs and then push up on the opposite side of the ring to remove
it.
• Remove the 3-piece oil ring with your thumbs in the same manner.
Speclanool - PIsIon RIngPRers: 51001·115
8-8 ENGINE BOTTOM END

Piston Installation
.Ap'plv engine oil:
Piston Pin
Piston Skirt
Cylinder Bore
.Oil Ring Installation:
a First install the expander in the piston oil ring groove so that the
expander ends [AJ butt together. Be sure that the expander end /3il
[8] is inserted into the expander holes.
a Install the upper and lower steel rails. There is no UP or DOWN to the
rails. They can be installed either way.

• Donot mix up the top and second rings. The top and second rings
are not symmetrical and must be instaHed with the marked side facing
up.
Top Ring [Al
Second Ring [B]
JON'" Mark [C]

.Position each 'piston ring end gap as shown.

AArtow
B. Top Ring End Gap, Upper Side Rail End Gap
C.45°
O. Second Ring End Gap,Lower Side Rail End Gap

.Assemble the pistons onto the connecting rods as shown.

o No. 1 cylinder piston, align the arrow on the top of the piston with
"MADE IN JAPAN'" on the connecting rod.
a No. 2 cylinder piston. align the alTOwon the top of the piston with
opposite "MADE IN JAPAW on the connecting rod.

A No.1 Cylinder Piston D. "MADE ,IN JAPAN"

B. No.2 CyIinderPistonE. Opposite "MADE IN JAPAN"
C. Arrow
 ENGINE BOTTOM END 8-9

eFit a new piston pin snap ring into the side of the piston so that the
ring opening CA] does not coincide with the notch [BJ in the edge of
the piston pin hole.

1. -----=----1
_ TIley cauId faD aut and . . . . . . cylinder waiL . _'

eUsing the piston ring compressor grip [A] and the belt [B], insert the
piston and connecting rod into the cylinder.
SpecIal TCtoI- PIaIGn" c:ompr..ar GrIp: 17G01-1.
PIIIan . . eompr•••ar .... CIII7 - cpJI: S7fI01-"-
o Insert the piSton and connecting rod so that the arrow [C] on the top
of the piston points toward the altsmator side.
o Ughtly tap the top of the piston with a plastic matlet to insert the Piston
and connecting rod into the cylinder.
eApply engine oil:
Crankpin
eTorque:
Torque - CoaIMICIIng Rod ... End ClIp Boll: it rNa (2.1 ...... 15.0
Nt)

Piston Ring, Piston Ring Groove Wear

eCheck for uneven groove wear by inspecting the ring seating.
*The rings should fit perfectly parallel to the groove surfaces. If not, the
piston must be replaced.
eWIth the piston rings i.n their grooves. make several measuraments with
81 thickness gauge [A1.to determine piston ring/groove clearance.
,
PIIIDn RIngIGraowe a. •• (TOp, SecGnd)
......... SenIce LIndI
Top OM - .... an 0.1' nun
Second 0.03 - om mm 0.17I11III

Piston Ring End Gap

e Place the piston ring inside the ~linder, using the piston to locate the
ring squarefy in place. Set it close to the bottom of the cvIinder, where
cylinder wete is low.
e Measure the gap between the ends of the ring with a thickness gauge.
PIlton Ring End Gap (Top, Second)
SIandIird: 0.2 - OA an
ServIce LImI: 0.7 mill
8-10 ENGINE BOTTOM END

Cylinder Inside Diameter

.Take.a side-to-side and a front-to-back measurement at each of the 3
locatIOns (total of 6 measurements) shown in the figure.
* If any of the measurements exceeds the service limit the ,cylinder will
have to be bored to oversize and then honed.
CylInder inside Dlamelar
Standafd: 75.980 - 76.000 mm and tess than o.01mm cIIIfer..
ence between anylwo measuremenlll
ServIce limB : 78.10 mm or more than O.05mm, dllarence betWeen
aDJ two measurements

Piston Diameter
• Measure the outside diameter of the piston 10 mm up from the bottom
of the piston at right angles to the direction of the piston pin.
* If the measurement is under the service limit replace the piston.

PIIIDa DI8m4dIr
Standard: 75.935 - 75.950 mm
UOL)
ServIce LImit 75.88 mal

Boring, Honing
When boring and honing a cylinder, note the following.
o Oversize piston requires oversize rings.
Oversize PIsIDn .... Rings
,0.50 mm 0YenI1ze
o Before boring a cylinder, first measure the exact diameter of the
oversize piston, and the., according to the standard clearance in the
S~ifications, detennine the rebore diameter. However, if the amount
of boring necessary wolJld increase the inside diameter by more than
0.50 mm, the crankcase must be replaced.
o Cylinder inside diameter must not vary more than 0.01 mm at any
point. .
o Be wary of measurements taken immediately after boring since the
heat affects cylinder diameter.
o In the case ot rebared cylinder and oversize piston, the service limit tor
the cyiinder is tihe diameter that the cylinder was bored to plus 0.1 mm
and the service limit for the piston is the oversize piston original
diameter minus 0.15 mm. If the exact figure for the rebared diameter
is unknown., it can be roughly determined 'by measuriing the diameter
at the base of the cyHnder.
 ENGIN'E BOTTOM END 8-11
Crankshaft and Connecting Rods

Connecting Rod Remov:al

• Remove the connecting rods during the piston removal.

Connecting Rod Installation

•.Install the connecting rodS during the piston installation

CrankshlIft Removal
• Remove:
Engine
Cylinder Head
Altemator Rotor and Stator
Crankcase Cover
Camshaft
Pistons and Connecting Rods
Crankshaft

Crankshaft Installation
.GI'88Se:
Oil Seal Ups.
• Apply engine oil:
Crankshaft. Joumal
.Install the crankshaft gear [Al with the chamfered s.ide faces In. The
cam timing mark [B] faces out

Crankshaft Cleaning
.After removing, clean the crankshaft with a high flash-point solvent.
.Blow the crankshaft oil passages [AJ with compressed air to remove
any foreign particles or residue that may have accumulated.
8-12 ENGINE BOTTOM END

Connecting Rod Bend/Twist

• Measure the connecting rod bend.
o Select an arbor of the same diameter as the connecting rod big end,
and insert the arbor through the connecting rod big '9nd ,.
o Select an arbor of the same diameter as the piston pin and at least 100
mm long, and insert the arbor through the connecting rod small end.
OOn a surface plate, set the big-end arbor on V blocks.
OWith the connecting rod held vertically, use a height gaug!' to measure
the difference in th'e height of the small end arbor above the swiace
plate over a 100 mm length to determine the amount of connecting rod
bend.
*If connecting .rod bend exceeds the service limit, the connecting rod
must be replaced.
eor-• •cllng Rod Bend
Standard: 0.G6l100 mm
Sana Llml: 0.21100 mm

• Measure the connecting rod twist

oWIth the big-end arbor still on the V blocks, hold the connecting rod
horizontally and measure the amount that the small end arbor varies
from being parallel with the surface plate over a 100 mm length of the
arbor to detemlinelhe amount of connecting rod twist
*If connecting rod twist exceeds the service limit, the connecting rod
must be replaced.
ConnecIIIIg Rod TWIll
SIandard: 0.081'100 rnm
Service LImIt 0.21100 mm

Connecting Rod Big End Side Clearance

• Measure connecting rod [A] big end side clearance.
o Insert a thiclmess gauge [8] between the connecting rod big ends and
either crank web to detennine clearance.
*If the clearance exceeds the service limit replace the connecting rods
with new ones and then check clearance again. If the clearance is too
large after connecting rod replacernant, the crankshaft must also be'
replaced.

Cor.'l8dIng Rod Big Enid Side CIearanC8

SIandard: o.s -1.1 mm
ServIceUmIt 1.3mm
 ENGINE BOTTOM END 8-13

Connecting Rod Big End Bearing/Crankpin Wear

Bearing/crankpiin wear is measured using, plastigauge (press gauge),
which is inserted into the clearance to be measured. The plastigauge
indicates the clearance by the amount it is compressed and widened
when the parts I.re assembled.
eMeasu.re the bearing/cmnkpm clearance.
o Remove the connecting rod big end cap and wipe the big end bearing
and crankpin surface clean of oil.
o Cut a strip of plastigauge to bearing, width, and place the strip [A] on
the crankpinfor the connecting rod paraUelto the crankshaft so that
the plastigauge will be compressed between the crankpin and the
bearing.
o InstaU the connecting rod big end cap and tighten fhe bigeild cap
bolts to the specified torque. '
Torque - ComecIInQ Rod BIg End cap BoIIIi : 21 Nom (2.1 kg-m, 15.0
Nt)

NOTE
o Do not turn the cranlcshaft during clealance measurement.
o Remove the connecting rod big end cap, and measure the plastigauge
width to determine the bearing/crankpin clearance.
Comacllrlg, Rod Bit EndBealinglCrankpln CIeaNnce
StandIIrd: U24 "" 0JI48 mm
Service Umlt o.oa mm
NOTE
o The cIeantnce·.,...· ·.fhen. 0.025 mm can not be measured by
plastigauge.
*isIf the clearance is within the standard, no connecting rod replacement
required.
*If the clearance is between· the standard (maximum) and the service·
. limit, replace the connecting rod.

elf the clearance exceeds the service limit measure the diameter [Al of
the crankpin.
*If the crankpin has wo,m past the service limit, replace the crankshaft
with a, new one.

CrankpIn DIameter
SIandarct 33S17 "" 33.180 mm
Service LImit 33.95 nun
The ,connecting rod big end inside diameter can be measured as
following .
• .Install the con'necting rod big end cap and tighten the big end cap
bolts to the specified torque.
Torque -ConneclfRg R.od Bit ERd Cap BoHa: 21, N-m (2.,1 kt-m, 15.0
II-Ib)
• Measure the inside diameter [A] of the connecting rod big end.
*If the connecting rod big end bore has worn past the service limit,
replace the connecting rod.

ComnacIIng Rod Big End InIIcIe DIameter

standard: 34.004- 34.01.5 mm,
Service Limit 34.05 mm
8-14 ENGiNE BOTTOM END

Crankshaft Runout
• Measure the crankshaft runout.
o Set the crankshaft in a flywheel alignment jig or on V blocks.
OSet a dial against both bearingjoumals.
OTum the crankshaft slowly to measure the runout The difference
between the highest and lowest dial gauge readings (liIR) is the
amount of runout
*If the measurement exceeds the service limit replace the crankshaft
CIankshaft Runout
Standard: Leas IIan 8.D2 mm nR
Servtce LImit: 8.05 mm 11R

Crankshaft Main Bearing/Journal Wear

• Measure the diameter [AJ of the crankshaft. main journal.
*If the joumal has worn past the service limit. replace the crankshaft
with a new one.
Crankshaft Main JoumaJ Diameter
Standard: 33.959 - 33.175 nun
SIrv,rce LimB: 33;94 mm

• Measure the inside diameter [AJ of the aankshaft main bearing.

*If the bearing has wom past the service limit replace the crankcase
bushing [8] and/or crankcase cover with a new one.
Crarahaft Mall'l1urIng inside Dlam.....
SIandard ServIce LIm.
33.117 - 34.084 mm 34.12,mm
34.025 ,.. 34.041 mm 34.10mm
 ENGINE BOTTOM E. ND 8-15
Breather Valve

Breather Valve Removal

• Remove:
Alternator and Stator
Breather Cover Bolts [A]
Breather Cover [B]
Breather Valve [C]

Breather Valve Installation

• Place the reed valve on the seat so that there 'is a slight gap between
the valve and t~ seat
Mounting Screw [A1
Back. Plate [B]
Reed Valve [C]
Gap [0]

.Be sure the drain badk hole [A] does not accumulate with slugges
beforeinstalliing the breather valve.
• Align center of the valve seat with center of the reed valve and back.
plate, tiler! tighten the mOlJnting sCrew.

NOTE
o The mounting screw isa self-tapping one. Be aware that
misthreading or overtightening- screw will strip the female .threads
and ruin tbe hole.

Breather Valve Inspection

• Inspect the reed valve for breakage, ha,i,T ,cracks or distortion, repl.ace it
if necessary.
• Inspect. the back plate for damage or rough contact surface, replace it
if necessary.
• Inspect the valve seating surface. The surfaoe should be free ·of nicks
or buns.
 TRANSMISSION 9-1

Transmission
T'able of Contents

Exploded View ...........................................................9-2 Hi/Low G,eair and Shift Mechanism

Specifications .................................... ". .........."................9-5 Inspection .............................."..........................9-14
Transm,ission Oil ...................................".....................9-6 2WD/4WD Shift Mechanism (KAF620A) ..............9-15
Transmission Oil Levef Inspection ........................9-6 2WD/4WD Shift Cable Adjustment ......................9-15
Transmission Oil Change .....................................9-6 2WD/4WD Shift Cable Lubrication ...................9-15
Tr:ansmission Case .................:...................................9-7 2WD/4WD Shift Cable Inspection .....................9-15
Tr:ansmission Case RemovaL ...............................9-7 2WD/4WD Shift Mechanism Removal .............9-16
Tr:ansmission Case Installation .............................9-7 2WD/4WD Shift Mechanism Installation ..........9-16
Transmissi,on Case Spli.tting ....................................9-7 2WD/4WD Shift Mech,anism Inspection ...........9-17 ~
Transmission Case Assembly ...................................9-7 D,ifferential Gears and Shift Mechanism ...................9-18 ~
Tr:ansmission and Shift Mechanism...........................9-9 Differential Shift Cable Adjustment .....................9-18
Tr:ansmission Shift Cable Adjustment ...................9-9 Differential Shift Cable Lubrication ....................9-18
Tr:ansmission Shift Cable Inspection ......................9-9 Differential Shift Cable Inspection .......................9-18
Tr:ansmission Remo·val ............................................9,-9 Differential Shift Mechanisml Removalll ..............9-18
Transmission Installation ......................................9-1 0 Differential[ Shift Mechanism Il'lstaUation· ..........9-19
Tr:ansmission and Shift Mechanism Differentia,l Shift Mechanism Inspection ............9-19
Inspection ." ....................."............. ". ................9-11 Differential Gear Removal ...................................9-.19
Hi/Low Gears and Shift Mechanism Differentia,1 Gear Installation ...................................9-20
(KAF620A) ....................................................9-12 Differential· Gear Inspection ................................9-20
Hi/Low Shift Cable Adiustment ............................9-12 Bearings and Oil Seal.................................................9-21
Hi/Low Shift Cable Inspecl:ion ..........................9-12 Bearing Repfacement ................".......................9-21
Hi/Low Gear and Shift Mechanism Removal ...9-12 Bal'i Bearing Inspection .. -. ..................................9-21
, Hi/Low Gear and Shift Mechanism Needle Bearing Inspection ...................................9-21
Installation ..........................................................9-13 Oil Seal Inspection ..............................................9-21
9-2 TRANSMISSI,ON
Exploded View

AD : Apply adhesive agent.

G: Apply grease. KAF620A
L : Apply nan-pennanent locking agent.
LG : Apply liquid gasket
0: ApplyoU.
•
T1: 7.8 N-ml (0.80 kg-m, 69 In-I)
12: 8.8 N-m (0.90 kg-m, 78 In-Ib)
13 : 15 N-m (1.5 kg-m, 11.0 II-Ib)
T4: 2.0 N.m (2.0 kg-m, 14.5 ft-lb)
T5: 29 N-m (3•.0 kg-m, 22 tI-Ib)
T6 : 37 N-m (3.8 kg-m., %11Mb)
T7: 44 N.m (4.5 kg-m, 33 ft.lb)
T8 : 120 N-m (12.0 kg-m" ~ ft-Ib)

KAF620A
 TRANSMISSION 9-3

KAF620A
9-4 TRANSMISSION

KAF620A

KAF620B

Optional

< T3
T2
 TRANSM ISSIO,N 9-5
Specificati'ons

Item Standard Service Umit

Transmission Oil:
Type API "Gl-5" Hypoid gear oil I
-. -- I

SA;E90: above 5°C (41°F) I

SAEBO: below 5°C (41 "F)

Capacity: KAF620A 2.5 l - --
KAF620B 2.2l -. --
Oil level Between upper and lower level lines - --
Transmission: I

Shift arm pin diameter 7.95 - B.oo mm

I
! 7.8mm
Shifter block inside diameter 8.05 - B.10mm I 8.2mm
Shifter block outside diameter 113.95 - 14.00 mm 13.8mm
Shifter ,groove width 14.0 - 14.2 mm 14.3mm
Drive chain 20-link length 158.76 -159.18 mm 1612mm
HilLow Shift Mechanism (KAF620A):
Shifter block outside diameter . 13.95 -14.00 mm 13.8mm
Shifter 'groove Width ; 14.05 -14.15 mm 14.3 mm
2WDl4WD Shift Mechanism (KAF620A):
Shifter block. ,outside diameter 13.95 - 14.00 mm 13.8 mm
Shifter groove width I 14.0 -14.2 mm 14.3mm
Differentilal Shift Mechanism,: I
Shift arm pin diameter '8.4 - 8.6mm 8.3mm
Shifter groove width, 9.0 - 9.1 mm
I 9.2mm

,SpecIal Tool - Praaaure cable Luber: K5I019-021

0uIIIcIe, CIrcIIp Pliers: 57001-144
Olt Seal & ....... RImoYer: 57001-1058
BearIng DrIver Set 57001-1121
Hexagon Wrench, Hex 32: 57001-1194
Sealanl- Kaw.... Band (LIquId GaUl - SIYer): 92104-002

NOTE
o Use the following ,tool only for the KAF62OA.
57001-1194
9-6 TRAN'S'MISSION
Transmission Oil

CAU110N
Vehicle operation wHh Insufficient, deteriorated or contaminated
. lransmlaalon 011 will cause accelended wear and may resull In
IJ'ansmIaaIon failure.

Transmission Oil Level Inspection

NOTE
o If the vehicle has just been used wait several minutes for all the oil
to settle down.
• Pa.n( the vehicle on level ground, and tilt up the cargo bed.
• Unscrew the oil filler cap [AJ, wipe its dipstick [8] dry. and insert it
into the fililer opening but DO NOT SCREW IT IN .
• Pullout the dipstick and check the oil level. The oil level should be
between the upper (H) a,nd lower (l) level lines [C].
*If.the oil level is too high. remove the excess oil, using a syringe or
some other suitable device, through the oil filler qpening.
.*If the oilleve! ,is too low. add the necessary amount of oil through the
oil filler opening. Use the same type and make of oil that is already in
the transmission.
NOTE
01/ the transmission oil type and make are unknown, use any brand
of the specified oil to top up the level in p.reference to running the
transmission with the oi/leve/Iow. Then, at your earliest C(Jnven-
fence, change the oil completely.

Transmission Oil Change

.Wann up the oil by running the vehicle so that the oil will pick up any
sediment and drain easily. Then stop the vehicle.
• Place an oil pan beneath the transmission case.
• Remove the transmission oil drain plug [AJ. and let the o,il drain
completely.
• Check the gasket at the drain plug for damage.
* Replace the gasket with a new one if it is damaged.
• After the oil has completely drained out install the drain plug with the
gask.et.
Torque - Transmission 011 Drain .PIUg: 15 N-rn (1.5 kg-m, 11.0 ft..1b)
• Fill the transmission case with a good quality oil as specified in the
table.
• Check the oil level.
Transm.l8sion 011
Type: AP''''GL..s'''. Hypold gear 011
SAE 90 above SoC (41"F)
SAE 80 below S·C (41 "F)
Capacity: KAF620A 2.5 L
KAF62DB 2.2 L
011 level: Between upper and lower leve' lines
 TRANSMISSION 9-7
Transmission Case

Transmission Case Removal

• Remove:
Transmission Oil (drain)
Cargo Bed
Propeller Slhafts (KAF620A)
Torque Converter
Throttle Cable tower End
GovemorAnn
O:mtrol Panel Assembly
Neutral Switch Terminal L.ead (disconnect)
Transmission Shift Cable tower End
Difterential Shift Cable lower End
Hi/tow Shift Cable lower End (KAF620A)
2WD/4WD Shift Cable tower End (KAF620A)
Cable Bracket Mounting Bolts [A] and Collars
Drive Shafts and Axles
Transmission Case Mounling Bolts and Nuts [B]
T'ransmission Case [C]
o Remove the sta,rter motor. engine mounting bolts, and/or rear end
sub-frame upper mounting bolts for extra clearance.

Transmission Case' Installation

.Torque:
Torque - T........ IaIonCaee MounIIngi 80118: 44 N-m (4.5 kg-m, 33 fI.Ib)
.Adjust
Engine Mounting Position (see Engine InstaUaltion)
Transmission Oil
Transmission Shift Cable
Differential Shift Cable
Hi/tow Shift Cable
2WD/4WD Shift Cable
Throttle Pedal Free Play

Transmission Case Splitting

• Remove:
Cable Bracket
Transmission Case Bolts [A]
Transmission Case (Left) [B]

Transmission Case Assembly

.,Check to see that the transmission case knock pins [AJ are inpl,ace.
If anyone of them has been removed, replace it with a new one.
• Apply !Iiquid g.asket:
Transmission Case "Mating Surface
Sealant - Kawasaki Bond (Ucp.l1d Gasket - Silver): 92104-002
.Apply grease:
Oil Seall Lips
9-8 TRANSMISSION

.Check that the governor shaft [AJ is turned clockwise.

eTtlrning the drive shaft [6]. engage the governor drive gear IC] with
the governor gear [0] .
• Torqtle.:
Torque - Transmission case Bolla: 8.8N-m (0.90 kg,,",. 78 In-Ib)
 TRANSMISSION 9-9
Transmissiion and Shift Mechanism

Transmission Shift Cable Adjustment

• Loosen the transmission shift cable adjuster nuts [A] .

• Position the shift shaft lever [A] so that the opening [8] in the clamp
is aligned with the mark: [C] on the transmission case.
NOTE
OAt this time, the transmission gfNIIS must: be in neutral

.'Slide the adjuster until the transmission shift level' [A] is in the neutral
position [8] .
• Tighten the adjuster nuts securely.

Transmission Shift Cable Inspection

.Wlth the cable disconnected at both ends, the cable should move
freely within the cable hollsing.
*If the cable movement is not free, if the cable is fulyed, or if the housing
is kinked, replace the cable.

Transmission Removal
• Remove:
Transmission Case (split)
Hi/Low Shift Giears (KA,F620A)
Drive Shaft [A]
Drive Shaft Reverse Sprocket [8]
Drive Chains [C]
9-10 TRANSMISSION

• Remove:
Shift Arm Position.ing Bolt Assembly [AJ
Retaining Pin [8]
• Lift the shift arm [C) and remove the shiftet-br6ck [0] .
• Remove:
Shifter [E]

• Remove:
Circlip [A]
Washer [8]
Drive Shaft Fol'Ward Gear [C]
Shift Ann [D]
Drive Shaft (OlJter) [E]
Special Tool - 0uII1de Clrclip PIIera: 57001·144

• Remove:
Circlips [Al
Washer [8]
Govemor Drive Gear [C]
Pin
Dr:ive Shaft [0]
SpecIal Tool - 0uIIIde Clrdlp Pi....: 57001·144

• Remo,ve:
Circlips CAl
Driven Shaft Reverse Sprocket [8]
Driven Shaft Forward Gear [e]
Driven Shaft [0]
Special 1:001- 0uIsIde CIrcIIp Pliers: 57001·144

Transmission Installation
• Repllace an circlips that were removed with new ones.
NOTiE
OAlways install eirclips so tj1at the opening is aligned with a spline
groove. To install a circlip without damage, first fit the circlip onto
the shaft and then expand it just enough to install. Hence, use a
suitBble Dear tn p,u~b th" circlip into place.
 TRANSMISSION 9-11

.Apply transmission oil:

Drive and Driven Shafts
Forward G,ears
Reverse Sprodkets
Drive Chains
.Apply grease:
Oil Seal Lips
Shift Arm Positioning Ba'" and Spring
.Torq,ue:
Torque - Shill Arm, PosIIIoaing 101: 37 Nom (3.8 ~. %1 ft.Ib)
.Install the shifter [A] $0 that the grooved side [8] faoes to the .
opposite side of the fo:rward gear [C] .
• Install the governor drive gear [0] so that the chamfered side [E] faces
to the flange [F] .
• Check that each gear, sprocket. and shifter .spins or slides freely on its
shaft without binding after assembly.

Transmission and Shift Mechanism Inspection

.VlSually inspect the forward gears, reverse sprockells, gear and shaft
bushings [AJ. drive chains, and shifter.
• Replace any of the above mentioned components should excessive
wear be observed.
Shill Ann PIn Diameter
StandaNl: 7.95 - 8.oomm
Service Llml: 7.8 mm
ShIller Block inside DiameIIer
Standard: &.05 - 8.10 mm
ServIce limit &2 mm
ShHler Block Outside Diamelar
Standard: 13.95 - 14.00 mm .
Service limit 13.8 mm
Shlflar GrooveWldlh
Standard: 14.0 - 14.2 mm
ServIce LImit 14.3 mm
Drive Chain :lO-I.fI* LengIh
Standard: 158.76 - 159.18 mm
Service Umlt 161.2 mm

1 2
9-12 TRANSMISSION
Hi/Low Gears and Shift Mechanism (KAF62OA)

Hi/Low Shift Cable Adjustment

• Put the shift lever [A] in the low position•

• Tum the shift shaft lever [A] clockwise until the lever is stopped by
engaging the shifter dogs with the dogs on the low gear.
NOTE
OAt this time. the IIhift shalt lever opening [8] is aligned with the matk
[C] on the hillow gear case. .
• Screw in the upper adjuster nut [0] by hand until the inner cable [E]
has no slack while holding the shift lever in the LOW position•
• Tighten the lower adjuster nut [F] securely.

• After ad)uSbnent. check the following.

OS1art the engine and put the transmission shift liver in the F (Forwan:t)
position.
o Move up and down the hillow shift lever [A] slowly.
o Check that each position makes a grinding noise of the high and low
gealS. Each position to make a !noise should be symmetrical [B] for
the center [C] of the slot on the boaRi.
o If it is not symmetrical, adjust the hillow shift cable again.

Hi/Low Shift Cable Inspection

.With the cable disconnected at both ends, the cable should move
freely within the cable housing.
*11 the cable movement is not free, if the cable is frayed. or if the housing
is kinked, replace the cable.

Hi/Low Gear and Shift Mechanism Removal

• Remove:
Driven Bevel Gear Case
Hi/Low Shift Shaft Lever
2WD/4WD Shift cable Lower End
Hi/LowGear Case Bolts [A]
Hi/Low Gear Case [B]
 TRANSMI:SSIO;N 9-13

• Remove:
Washer (A]
High Gear [B]
Shifter Ie]
Reduction Gear [D]

• RemoVe:
Circlip, [A]
Washer [BJ
Low Gear [C]
Collar
SpecIal Tool - 0uII1cIe Clrcl" Pliers: 57001·144

• Remove:
Bolt [AJ
Holder [8]
Retaining Pin [e]
Shift Shaft and Arm [OJ

Hi/Low Gear and Shift Mechanism Installation

.AppIy transmission oil:
Hi/LowGears
Shifter
• Apply grease:
Oil Seal Lips
• Replace the circlip that was removed with a new one.
NOTE
OAlways install the circlip so that the opening is aligned with a spline
groove. To install a circ/ipwithout damage, first fit the circlip onto
the shaft and then expand it just enough to install. Hence, use a
suitable gear to push the circlip into place.
• 'nstall the shifter [A] so that the large dogs [BJ face to the low gear
[C].
9-14 TRANSMISSION

• Check to see that the hi/low gear case knock pins [AJ are in place on
the transmission case. If anyone of them has been removed, replace
it with a new one.

• Fit the shift ann pins [Al into the shifter grooves [8J.
.torque:
T~ - HIILaw Gear c.. BollI: 20 Nom (2.0 kg-m,1U8-Ib)
.Check that each gear and shifter spins or slides freely on its shaft
without binding after assembly.

. Hi/Low Gear and Shift Mechanism Inspection

.ViSually inspect the hi/low gears, shifter, and gear bushing [AJ.
ShIIIr 8Ioc:k 0UIsIda 0 .......
Standard: 13.85 -14.00 mm
ServIce limit 13.8 mm
..... Groove WIdIh
SIaIIdard: 14.85 - 14.15 mm
ServIce LImit 14.3 mm
 TRANSMISSION 9-15
.2WD/4WD Shift Mechanism (KAF62OA)

2WD/4WD Shift Cable Adjustment

.Put the shift. lever [A] in the 4WO position .

• Tum the shift shaft lever [A] counterclockwise until the IEMH' is
stopped by engaging the Shifter dogs with the dogs on the drive bevel
gear shaft
.Screw in the upper adjuster nut [8] by hand until the inner cable [C]
has no slack while holding the shift lever in the 4WO position .
• Tighten the lower adjuster nut [0] securely.

NOTE
Off the2WD/4WD shift cable cannot be adjusted by using the
adjuster at the shift shaft lever, use the .adjuster [A] at the shift lever.
Do not forget to .tighten the adjuster nuts [8].

2WD/4WD Shift Cable Lubrication

Whenever the shift cable is removed, lubricate the cable as foUows.
• Apply a thin coating of grease to the cable ends.
.Lubricate ~he cable with a penetrating rust inhibitor th,rough the
pressure cableluber.
SpecfaITooI- PreIaure CalM Lubar:K5I01J.021

2WD/4WD Shift Cable .Inspection

,.Wlth the cable disconnected at both ends, the cable should move
freely within the cable hOU$ing.
* If the cable movement is not free, if the cable is frayed, or if the housing
is kinked, replace the cable.
9-16 TRANSMIS·SION

2,WD/4WD Shift Mechanism Removal

• Remove:
Hi/low Gear Case
Shift Shaft Stop Bolt [AJ
Shift Shaft Lever Mounting Nut [B]
Shift Shaft Lever [e]
Spring [0]
Shift Shaft and Arm [EJ

• Remove:
Shifter [AJ
eirclip [B]
Speedometer Gear [e]
Collar
Specfal Toot - 0uIsIde Clrcllp PlIers: 57001..144

2WDj4WD Shift .Mechanism Installation

eApply grease:
Shift Shaft O-ring
.Install the shift shaft lever [A] to the shift shaft arm [B]as shown.
TOI'CP' ':"Stlift Shall Slop Bolt : 7.8 N-m (0.80 .kg-rn, 69 In-Ib)

.Install the speedometer gear [AJ so that the stepped side [IB] faces in.

• ,Replace the circlip that was l'ernoved with a new one.

NOTE
OAlways install the circlip so that the opening is aligned wfth a spline
groove. To install a circlip wfthoutdamage, first fit the circfip onto
the shatt and then expand it just .enough to install Hence, use a
suitable gear to push the circlip into place.
 TRANSMISSION 9-17

2WD/4WD Shift Mechanism Inspection

.Visually iinspect:
Dogs on Shifter [A]
Shifter Groow [8]
Dogs on OrNe Bewl Gea1r Shaft [C]
Shi,fter Block [D)
*If they are damaged or wom excessivelv, replace them.
Shiller Black OutsIde Diameter
S1aIdIrd: 13.95 - 14.00 mm
ServIce Umlt 13.8 mm
Shiller Groove WIdIh
SII8ndard: 14.0 -14.2 mm
Service LImit: 14.3 mm
9-18 TRANSMISSION
Differential Gears and Shift Mechanism
Differential Shift Cable Adjustment
• Put the shift lever [A] in the LOCK position.

• Tum the shift shaft lever [A] clockwise until the lever is stopped by
engaging the shifter dogs with the dogs on the differential gear•
• Screw in the upper adjuster nut [B) by hand until the inner cable [C]
has no slack while holding the shift lever in the LOCK position•
• Tighten the lower adjuster nut [0] securely.

Differential Shift Cable Lubrication

Whenever the shift cable is removed, lubricate the cable as follows.
.Apply a thin coating of grease to the cable ends.
• lubricat8 the cable' with a penetrating rust inhibitor throughth,e
pressure cable luber.
SpecIal Tool ~ ......... QIbIe Luber: K5R1N21

Differential Shift Cable IrtspeCtion

.Wlth the cable disconnected at both ends, the cable should move
freely within the cable housing.
*If the cable movement is not free, if the cable is frayed, or if the housing
is kinked, replace the cable.

DiRerentil!l Shift Mechanism Removal

• Remove:
Drive Shafts and Axles
Shift Shaft Stop Bolt [AJ
Shift Shaft Lever Mounting Nut [8]
Shift Shaft Lever [el
Spring [0]
Shift Shaft and Arm [E]
 TRANSMISSION 9-19

Differential Shift Mechanism Installation

• Apply grease:
Shift Shaft O·ring
• Install the shift shaft leYer [A] to the shift arm [8] as shown.
Torque - Sh. Shaft Slop Boll : 7.8 NioI11 (0.80 kg-m, 69 In-Ib)
1

Differential Shift Mechanism Inspection

.Visually inspect
Splines on O'riVe Shaft [A]
Splines on Shifter [8] .
Dogs on Shifter
Shifter Groove
Dogs 00 Differential! Gear Housing [C]
Shift.Arm Pil'l [0]
*It they are damaged or worn excessively, replace them.
Shill Ann Pin Diameter
Standard: 8A - 8.8 mm
Service Umlt 8.3 nun
Shiller Groove WIdII
SIandard:9.0 -9.1 min
ServIceUmIt '9.2,nun

Differential Gear Removal

• Remove:'
Transmissiol'l Case (split)
Differential Gear Assembly [AJ
9-20 TR.ANSMISSION

• Remove:
Differential Gear Housing Bolts fA]
Final Gear ['B]
Knock. Pins [C]

• Renlove:
Housing Cover [A]
Knock Pin [8]
Side Gear [C]
Spacer [0]
Retaining Pin [E]
Pinion Gear Shaft [F]
.Pinion Gears [G]
Spacers [H]
Side Gear [I]
Spacer [J] .

Differential Gear Installation

.'Applv transmission oil:
Side Gears
Pinion Gears
.Apply non-pennanent locking agent
Oiflerential Gear Housing Bolts
.Torque:
T~ - DIIJerenIJaJ GearHoualag Bolli : 29 N-m (3..0 kg-m, 22 ....Ib)

Differential Gear Inspection

.Visually inspect the differential gears.
*.Replace the gears as a set if either gear is damaged.
 . TRANSMISSION 9-21
Bearings and Oil Seal

Bearing Replacement
.Using a press, a puller, tile oil seal & bealringi remover,. or tile bearing
driver set remove the bearings.
SpecIa.1 Tool - 011 Seal & Bearing Remover: 57001-1058
Bearing Driver Set 57001-1121
.Usling tile hexagon wrencll '[A], remOYe the bearing holder [8] and
remove the drive bevel gear shaft bearing.
Special Tool - Hexagon Wrench, Hex 32: 57ODI-1184
.Appllyoil:
Drive Bevel Gear Shaft Bearing Holder
.Torque:
Torque - BearIng Holder: 120 N-m (12.0 kg-m, 871W11i)
• Using a press and the bearing driWer set, install the new bearings
and/or new oil seals.
SpecIal Tool - BearIng DrIver Set 570Cn-1121

Sa//Searing Inspection
.Tum each bearing back and forth while ch;ecking for roughness or
binding.
*If roughness or binding is found, replace the bearing •
• Examine the bearing seal for tears or leakage.
* If the seal is tom or is leaking, replace the bearingl.

Needle Bearing Inspection

.Check the needle bearing.
OThe rollers in a needle bearing ,nonnally wear very little, and wear is
diffICult to measure. Instead of measuring, inspect the bearing for
abrasion, color change, or other damag,e.
*Ifthere is any doubt as to the condition of a needle bearing, replace it

Oil Sea/Inspection
eVisual!ly inspect the oil seal.
*Replace it ,if the lips are misshapen, discolored (indicating mat the
rubber Ilas deterio~), hardened, or been otherwise damaged.
9-22 TRANSMISSI'ON

KA'F620A
 TRANSMISSION 9-23

KAF620B
9-24 TRANSMISSilON

KAF620A
 WHEELS I TIRE.S 10-1

Wheels I Tires
Table of Contents

Exploded V:ie'N .............................................................................................................10-·2

Specifications .....................................................................................................................10-3
Wheel Alignment .............................................................................................................;1 0-4
Toe-in Adjustrnent ...............................~ .................................................................10-4
Wheels (Rims) ..........................................................................................................10-5
Wheel R:em·oval .........................................................................................................10-5
Wheel Installation ......................................................................................................10-5,
Wheel (Rim) Inspection ..,........................................................................................10-5
Wheel (Rim) Replacement .......................................................................................10-6
Tires .........................." ..................: ...............................................................................10-7
Tillre Removal .......................................................................................................,.. 10-7
Tire Installation ..........................................................................................................10-7
Tire Inspection .......................................................................................................10-8
10-2 WHEELS I TIRES
exploded View

11 : 98 N-m (110.0 kg-m, 72 ft-Ib)

. ;
 WHEELS I TIRES 10-3
Specifications

Item Standard Servilce Umit

Wheel Alignment:
Caster 1.5 (non-adj.ustable)
0
- --
earnbel' 0.8" (non-adjustab11e) - --
Toe-in I
0- 20mm - --
Tires:
Standard tire: KAF620A 22 x11.00-1 0
Dunlop KT869A Tubeless - --
KA.F620B 20 x 10.00-10
, Goodyear Power Rib Tubeless
Tire air pressure (when cold):
KAF620A: Front SO kPa (O.S kg/e~, 12 psi) - --
Rear 180 kPa (1.S kg/em2 , 26 psi) - --
KAF620B: Front 80 kPa (0.8 kg/em:!, 12 psi) - --
I
Rear 140 ~Pa (1.4 kg/enr, 20 psi) - --
Maximum tire air pressure 250 kPa (2.5 kg/em:!, 36 psi) - --
(to seat beads, when cold)
Tire tread depth: KAF620A i 13.2mm 3mm
KAF620B !Smm 3mm
10-4 WHEELS / TIRES
Wheel Alignment
Toe-in is the amount that the front wheels are closer together in front
than at the rear at the axle height When there is toe-in, the distance A
(Rear) is greater than B (Front) as shown. The pU'rpose of toe-in is to
prevent the front wheels from getting out of paral.lel at any time, and to
prevent any slipping or scuffing action between the tires and the ground.
If toe-in is incorrect, the front wheels win be dragged al.ong the ground,
scuffing and wearing the tread knobs.
Caster and chamber are built-in and .require no adjustment

A (Rear) - B (Front) = Amount of Toe-in

(Distance A and 8 a.re measured at hub height)

Toe-in Adjustment
• Lift the front wheels off the ground .
• Apply a heavy coat of chalk near the center of the front tires.
• Using a needle nose scriber, make a thin mark near the cemter of the
chalk coating while turning the wheel .
• Set the wheels so that the mal1<s on the tires a,re at the front side and
at the level of the axle height
.Ground the front wheels.
• Set the steering wheel straight ahead .
• At the level of the axle height, measure the distance between the
scribed lines with a measure. .
• Move the vehicle rearward until the marks on the front,tires are at th~
rear side and at the same level as the axle.
• Measure the distance between the scribed lines.
• Subtract the measurement of the front from the measurement of the
rear to get the toe-in.
Toe-In 01 Frant Wheels
Standard~ 0 ~ 20 mm
*If the toe-in is not the specified value, perform the following
procedure.

• Loosen the locknuts [AJ on each tie-rod and tum the adjusting :rods
[B] the same number o,f turns and the same direction on both .sides to
achieve the ~ified toe-in.

NOTE
o Th.e fDe-in will be near the specified range, if the length of the tie-rod
distance between the rod groove [A] and the locknut [8] is 51.5
mm [C] on both the left and right tie-rods.
• Check the toe-in again .
• Torque:
Torque - TIe-f'ocI End LocknuIa: 48 N-m (S.O kg-m, 36 ft-lb)

.Test ride the vehicle.

 WHEELS I TI:RES 1'0-5
Wheels (Rims)

Wheel Removal
eLoosen the wheel nuts (Do not remove).
eLift the wheel(s) off the ground.
eRemove:
Wheel Nuts
Wheel(s)

WheeilnslBlIation
e Position the wheel so that the valve stem [AJ is toward the outside of
the vehicle•
• Torque:
'-.e - Wheel NuIs :98 ..... (10.0kg-m, 72 ft-Ib,)
eTlghtenthe wheel nuts in a criss-cross pattern..

Wheel (Rim) Inspection

.Examine both sides of the rim tor dents [Al'
e If the rim is dented.• replace it.

elf the tire is removed, inspect the air sealing surfaces [A] of the rim for
scratches or nicks. Smooth the sealing surfaces with fine emery cloth
if necessary.
10-6WHIEELS I TIRES

Wheel (Rim) Replacement

• Remove the wheel.
• Disassemble the tire from the r,im.
o Remove the valve stem and discard it

1_. . . . Ive_~Io_
Do nat,.... ... air ¥II1ve..

Plastic Cap [AJ

Valve Core [BJ
Stem Seal [C]
Valve Stem [0]
Valve Seat [E]
Valve Opened [F]

.lnstaU a nSIN air valve in the new rim.

o Remove the .valve cap, lubricate the stem with a soap al1d water
solution. and pull the stem [AJ through the rim from the inside out
until it SI'laps into< place.

...-.
I-_... _ ~ :
Do not '... engine 011 or peIIIoIetn d....... 10 lubricate lie stem
I
.Mount the tire on the new rim .
• Install the wheel.
 WHEELS / TIIRES 10-7
Tires
TkeRemova{
• Remove:
Wheel
Valve Ca,re (let out the .air)
• Lubricate the tire beads and rim flanges on both sides of the wheel
with a SDaiP and water sollution. or water [A]. This helps the tire beads
slip off the rim! tlanges.

CAU110N

peIraIIum dlltllIIIaI: -=--,...,

Do noI lubricate ... lIN beeda. and rim ......... eagIna 011 or
will delerloralalhe Ure.

• Remove the tire from the rim using a suitable commercially available
tire changer.
NOTE
o The tires cannot be removed with hand tools because they fit the
rims .tightly.

Tire lnstallation
• Inspect the rim.
• Check the tire fur wear and damage.
• Replace the air valve with a new ooe.

I-.. . .--~ . -
Do not ,..... Iha .... valve.

• Lubricate the tire beads and rim flanges with a .soap and water
solution. or water.

n ,'/;:'RNING

Do not . . file IIabrtcIuIt oIhIr llana waIer and soap aoIuIIon, or

...... 11)ItiIIbrbdII ..... beIICII and rim because It mar _ Ire
.' .........., and ahazlnauacandllon may result.

.Install the tire on the rim using a suitable commercially available tire
changer.
• Lubricate the tire beads again and center the tire on the rim .

• Support the wheel rim [AJ 00 a suitable stand [8] to prevent the:tire
fiom slipping off.
• Inflate the tire until the tire beads seat on, the lrim.
Maxlmuln TIre AIr Presaure (10, Mat bNde ..... cold)
froid and Rear: _ kPa (2.5 kglanz, 36 pal)

~II.WARNINC;

Do ne11lnt1a1e IheIlN 10 maN . . . . the maximum, lira .... ~re.

Ovwfnlldlon can explode . . lire will ........,of Iajgy and Iaea
of I...
10-8 WHEELS I TIRES

.Check to see that the rim lines '.[A] on both sides of the tire a.re parallel
with the rim flanges [.B].
*If the rim lines and the rim flang'es are not parallel, deflate the tire,
lubricate the sealing surfaces again, and reinflate the tire .
• After the beads are properly seated, check for air leaks.
OApply a soap and water solution around the tire bead and check for
bubbles.
• Check the tire pressu.re using an air pressure gauge.
NOTE
o Kawasaki prov:ides the airpressure gauge (P/N52005-1031) as the
ownelstool
TIre Air Pressure (when coId)[KAFUOA]
Front 8D '/cPa. (0.8 kgIcm:l, 12 psQ
Rear: 180 /cPa (1.8 kg/W. 21 pal)
TIre Air PrestIure(when coId)[KAFI208]
Front 80 /cPa. (0.8 qlcm2 , 12 psi)
Rear: 140 /cPa (1A ~. 20 lpal)
.Install the wheel .
• Wipe off the soap and water solutio.n, or water on the tire, and dry the
. tire before operation.

i,,"WARNING
Do noI opend8 lie Y8h1c1e willi lie W1IIer and soap, or water stili
around the lire beacII. 1heJ' wiD CIlIiM tire ~. and a
hazarc:Iaus condIIIon may ......

Tire Inspection
.Examine the tire for damage and wear.
o If the tire is cut or cracked, replace it
o Lumps or high ~pots on the tread or sidewalls indicalteintemal damage
requiring tire replacement
o Remow any foreign objects from the tread. After removal, check for
leaks with a soap and water solution .
• Measure the uead depth at the center of the tread with a depth gauge.
Since the tire may wear unevenly, take measurements art several places.
*If any measurements is less than the service limit, replace the tire.
11ra tread·DepI'I [KAFU8AJ
.StandanI: 13.2 111m
ServIce Uml: 3 111m
TIre tread DepIb [KAFI208]
SIIRdud:. I mm
SenIce LImit: 3 mm
Standenl11re [KAFI2OA]
Front ...... : 22 x 11 • •10 DUNLOP 'KT869A Tubeless
SIaIIdIIrd"" [KARI208J
FronI and rear: 18 x. 10.00-10 GoodJ88r Power Rib T......
 IFINAL DRIVE 11-1

Final Drive
Table of Contents

Exploded View ............................... ". .......... ". .......... J 1-2 Bevel Gear Case Disassembly ...........................11: -16
Specifications ..........................................................11 -4 Bevel Gear Case Assembly...................................11-17
Front Final Gear Case (KAF620A) ........................ 11-5 D'rive Bevel Gear Removal .................................11 -118
Front Final 'Gear Case Oil Level Inspection ......... 11-5 Drive Bevel Gear Installation ............................11 -118
Front Fina.1 Gear Case Oil Change ...................... 11-5 Bevel Gear Adjustment ......................................11 -1! 8
Front Final Gear Case Remova,l ............................ 11 -6 Bevel Gear Inspection ......................................111 -21
Front Final Gear Case Installation ........................ 11-6 Ball Bearing Inspection .......................................11 -21
Front Final Gear Case Disassembly .................... 11-6 Oil Seallns.pection ...............................................11-21
Front Final Gear Case Assembly ........................11-7 Damper Inspection ..............................................11-21
Differential Unit and Ring Gear Disassembly ....11-7 Propeller Shafts (KAF620A) ..................................11 -22
Differential Un it and Ring Gear Assembly ........:.11 -7 Propeller Shaft Removal... .................................11-22
LSD Clutch Torque Inspectio" .............................11-8 Propel.ler Shaft Installation ...............................11-22
LSD Clutch Plate Inspection .................................11-9 Propeller Shaft Inspection .................................11 -23
Pi"ion Gear Unit Disassembly ..............................11-9 Drive Shafts and .Axles ...........................................11-24
Pinion Gear Unit Assembly ..................................11-9 Front Drive Shaft and Axl,e Removal r-:;:;l
Front Final Bevel Gear Adjustment ...................11 -10 (KAF620A) ..................................;.................11-24 ~
Bevel Gear 'I'nspection ........................................11-15 Front Drive Shaft and Axle IlnstaUation
Differential Gealr Inspection ................................11-15 (KAF620A) ......................................................11-24
Taperedl RoUer Bearing Inspection ...................11-1'5 IRear Drive Shaft and Axle Removal ................ 11 -24
Ban Bearing! Ins.pection .. ". ................................11-15 Rear Drive Shaft and Axle Installation ............. 11 -25
Oil Seal Inspection ...........................................11 -15 Drive Shaft and Axle Inspection ......................... 11 -25
Bevel Gear Case (KAf620A) .........................:....... 11 -16 Dust Boot Inspectio.n .................................. _.... 11-25
Bevel Gear Case Removal .........................". ...... 11 -16 ,Ball Bearing Inspecti10n .................................... 11 -26
Bevel Gear Case Installation .............................11 -16 Grease Seallnspection ....................................:11-26
'1-2 FINAL ORlVE
Exploded VIeW

G:Applyg.......
L : Apply non-p&nIIaWIt locking agent.
.. : Apply molybdenum dlllullde ......
0: AppIyoH.

n : U N-m (0.10 Irg-tn, 78 In-Ib)

12: 20 N-m (2..1rg-tn, 14.5 ft.Ib)
13: 22 tHn (2.21rg-tn, 18.0 ....)
T4: 25 N-m (2.51rg-tn, 18.8 ....'
15: 21 Nom p..1rg-tn, 22 ....'
18: 32 N-m (3.31rg-tn, 24 ....'
T7: 44 N.m (4.5Irg-tn, 33 ft.Ib)
18: 47 N-m (4.8 q.m, 35 I-Ib,
11: 48 Nom (5.0 Irg-tn, 31 Nt)
no: 11. Nom (11.8 kgom, 80",
. ,"1: 120 Nom (12......., fR...,
 FINAL DRIVE 11-3

. KAF620A
111-4 FINAL DRIVE
Specifications

Item Standard Service Limit

Front Final Gear Case (KAF620A):

Gear case oil.: Type AP'I "GL-5" hypoid gear oil for LSD
(limited Slip Differential gears) I -. -. -
SAE140 or SAE85W -140 -, -. - I

Capacity 10.. 4 L - -,-

Oil level
I
Fmer opening level - --
LSD clutch torque 7.8 .... 13.0 N-m
(0.8 -1.3 kg-m, 69 .... 113 in-Ib) - --
Outside friction plate thickness 2.3 .... 2.4 mm 2.1 mm
Inside friction plate thickness 2.7 .... 2.8 mm 2.4mm
Pinion gear bearing preload 0.3 .... 0.6 N-m '!
i
(0.03 .... 0.06 kg.-m, 2.6 .... 5 . 2 in-Ib)
I
-, -,-
Bevel gear baclklash 0.09 .... 0.20 mm I

(at ring gear tooth) - -- I

Bevel Gear Case (KAF620A):

BeVel gear backillash 0.08 .... 0 . 18 mm
(a,t housing locknut groove) - --
SpecIal lool - Bearing Puller: 57001-135
Outside CIn:IIp Pliers: 57101-144
Bearing Driver. 57001-382
DaU Gauge H~1der: 57001·1048
on Seal & Bearing Remover. 57001-1051
BearIng Driver Set 57001·1121
Pinion Gear Holder: 570014281
Socket Wrench: 57001·1283
PIn,1an Gear Holder: 57001·1285
Hexagon Wrench, Hex4&: 57001·1324
5ael: Wrench: 57001-1383
Transmission Gear Holder: 57101·1364

NOTE
o Use the lollowing tools only fo, the KAF620A.
57001-135
57001-382
57001-1049
57001-1281
57001-1283
57001-1285
57001-1324
57001-1363
57001-1364
 FINAL DRIVE 11-5

Front Final Gear Case (KAF620A.)

Front Final Gear Case Oil Level Inspection
• Park the vehi!c!e so that :itislevel. both side-to-side and front-to-rear.
• ,Remove:
Front Final G,ear Case Skid Plate [A]
Filler Cap [8]

Be careful not to allow any dirt orlorelgn !maIaria.• to enIer . . gear :

case.

• Check the oil level. The oil level should come to the bottom of the filler
opening [C].
*If it is insufficient. first check tile front fina·' gear case for oil leakage,
remedy it if necessary, and add oil through the filler opening. Use the
same type and brand of oil that is already in the final gear case.
• Be sure the O-ring. is in place. and tighten the filler cap.
Torque - 011 FIller Cap: 29 N-ml (U Icg-m, 22 ft.Ib)

Front Final Gear Case Oil Change

.Warm up the oil bV running the vehicle so th8t the aU will pick up allV
sediment and drain easily.. Then stop the vehicle.
• Park the vehicle so that ,it is level,. both side-to,;side and front-to-rear.
• Remove:
Front Final Gear Case Skid Plate
• Place an oil pan beneath the front final gear case and remove tine dralin
pilug [A].

Front final Gear case 011

Type : API "GL-5" hypolcl gear 011101' LSD,
(Umltecll Slip Dllerenllalgears)
SAE 140 or SAE85W-140
C'apacfty : 0.4 L

NOTE
0" GL -5" indicates a quality and additive rating.
• B'e slire the O-ring is in place,. and tighten the filler cap.
Torque - 011 FIller Cap : 21 N-m p.O ,kg-m, 22 fI-I))

" .. WARNING
When draining or mUng the final gear case, be caralullhal ,no 011 geI8
on the Ire or 'rhn. Clean aft any 011 IhaIlnadverlenlly gels on Iham
with •. hlgh-fla8h point solvent.

.After the oil has completely drained out i:nstall the drain plug with a
new aluminum gasket, and tighten it
~orque - 01 Drain Plug: 20 N-m(2.0 kg.m, 14.5 ft-Ib)
.RII the gear case up to the bottom of filleropenilng with the oil
specified above.
11: -6 FINA.L DRIVE.

Front FinalGeat Case .Removal

• Remove:
Front Fina.1 G,ear Case Skid Plate [A]
Front Fina.1 Gear Case Oi.l (drain)
Propeller Shafts
Front Axles and DTlive Sh~
Front Fina,IGear Case Mounting Bolts and Nuts [B]
Front Final Gear Case Bracket Bolts [C]
Front Finall G,earCase Bracket [0]
Front FinailGearCase [E]

Front Final Geat Case Installation

.!Route the gear case vent hose conectly.
• Apply non-permanent locking agent
Gear Case BraCket Bolt Threads
.Torque:
Torque - Gear Caae Brac:IkeI iBolla: 44 N-m (4.5 kg-m, 33 ft.II)
Gear caae MOUldIng iNUII: 44 N-m (4.5 ~. 33 ft.Ib)
.Adjust:
Front Final Gealr Case\Oil

Front Final Geat Case Disassembly

.iRemove:
Front Final Gear Case
Bearing Housing NU1s [A]
Pinion Gear Unit [B]

• Remove:
Ring Gear Cover BOb
Ring Gear Cpver
o Remove the ring gear cover bolts•. staring with the smaller bolts.
Smaller ~olts [A]
larger Bolts [B]
Pry Points [C]

• Remove:
Ring Gear [AI
Differential Unit [B]
 FINAL DRIV,E 11-7

Front Final Gear Case Assembly

.Visually check the pinion gea.r and ring gear for scorilng, chipping, or
other damage.
* Replace the bevel gears as a set if either gear is damaged since they
are lapped as a set in the factory to get the best tooth contact.
• Check that the ring gear is instaliled on the com~ctside of the differ-
ential caps [Alas shown .
• Install the fol,lowing parts in the order listed.
Differential, Unit and RiingGear
Ring Gear Shim [8]
Ring Gear Cover Pinion Gear Unit

.Install the pinion gear unit with the ring gear side of the case facing
down.
• Align the air vent passage [A] with the hose nipple (B].
e First tighten the 10 mm bolts, then ti,ghten the 8 mm bolts.
Torque - 10 mm Ring Gear Cover Boll :47 N-m (4.8kg-m, 35 Nt)
8 mm Ring Gear Cov8r BoIIis: 25 N-m'(2.S kg-m, 1&0 ft.I»)
PInion Gear 'BearIng HoI.BIng NuIB : 25 N-m (2.5 kg-m, 18.0
ft.I»
.Adjust:
Front Final Gear Backlash
Front Final Geair Tooth-Contact

Differential Unit and Ring Gear Disassembly .

• Remove the differential unit and ring gear (see Front Final, Gear Case
Disassembly).

I Do . . _ .. _=-_~ . ___ I
• Remove the following pa,rts to disassemble the differential unit
Ring Gear Bolts [A] Differential Caps [C]
Ring Gear [8] Mark here to assemblelatef [0]
" e The clutch plates, springs, spring shims, and side g'ears ,come out

Differential Unit and Ring Gear Assembly

Be AI,. 10 Install lie rigid and left aide parIS oIlhe unit Inlhe original
poslllon•

• Inspect the clutch plates (see Clutch Plate Inspection) and the other
differential unit parts. Replace any damaged parts.
• Measure and record the thickness of the Original clu1iCh spring shim(s) .
• Apply specified gear oil to the differential unit parts.
• Note direction and position ·of the friedon plate and the Clu1iCh spring..
CIU1iCh Spring Shim(s) [A] Steel P'l:ate [0]
Clu1iCh Spring, [B] Inside Friction Plate [.E]
Outside Friction Plate IC]
11-8 FINAL DRIVE

• Be sure to assemble the differential unit and inspect the clutch torque
(see LSD Clutch Torque Inspection).

Tapped Holes [AJ for Ring Gear

Mark [B] for assembly

.Install the kant axles [C] to center the steel plates.

• Apply non-pennanent locking agent:
Differential Case Torx Bolts [DJ
Torque - Dllerenllel Case Torx 1018 : 32 N-m (3.3 ..... 2C ft.Ib)
RIng Gear BollI : 41 N-m (5.:0 kg-m, 31 I-Ib) .

LSD Clutch Torque Inspection

.After assembling the differential unit and ring gear, check the LSD
clutch torque.
• IRemove the ring gear from the differentiaillulit [A] .
• lllnsert both front axles and drive shafts [B] in the unit
• Hold one of the front axles with a 'roIise.
• Install the hub nut. on the other axle.
eMeasure the clutch torque using a torque wrench [C]. Tum the
wrench evenly.
oThe clutch torque is t.he mean torque readingl du.ring about a quarter
tum of the wrench.
LSD CIuIch Torque
Standard: 7.8 -13.0 IN-m(O.8 -1.3 kg-m, 69 -1131n-1b)
*differential
If the clutch torque is Ollt of the specified range, disassemble the
unit (see Diifferemial Unit and Ring Gear Disassembly) and
replace either of the clutch spring shim(s) .
• Also, check the clutch plates and replace them as necessary (see
Clutch Platel,nspection).
eTo increasec,lutch torque, incrrease the thickness of the shim(s).
o Change the thickness a little ata time.
• Recheck the clutch torque and readjust as necessary.

Thickness Part Number

(mm)
0.8 92180-1121
1.0 92180·1! 1 22
1.2 92180-1' 123
1.4 92.180-1124
1.6 92180-1125
 FIINAL DRIVE 11-9

LSD Clutch Plate Inspection

.Visually inspect the friction plates and steel plates to, see if they show
any signs of seizure, ovel"heating,or uneven wear.
- ~ -10-
r®1
* If any pl:ates show signs of damage, or if the friction plates have worn
,.
past the service limit, replace the friction p'lates and steel plates as a set
Outside Friction Plate [A]
Inside Friction Plate [B]-

0uIsIcht FricIIon Plata ThICkness

S1ancIard: 2.3 - 2A mm I

Service limit 2.1 mm

Inside FrIcIIon Plaia ~
Standard: 2.1 - 2.8 nun
Service limit 2A mm

Pinion Gear Unit Disassembly

• Remove the pinion gear unit (see Front Final Gear Case Q:isassembly) •
• Pry open the toothed washer tab ,on the pinion gear slOtted nut
.Unscrew the pinion gea~ slotted nut
SpecIal Tool - PtnIDII Gear Holder. 57001·1281 [A]
Socket Wrench: 57001-1283 [B]
.'Remo,ve the slotted nut, flat washer, and toothed washer.
• Pull the pinion gear out of the beariing housing.
• ~Remove the tapered roller bearing inner race as necessary.
SpecIal 1001- BearIng Puler: 57G01·135

Pinion Gear Unit Assembly

.The pinion gear and ring gear a.re lapped as a set in the factory to get
th,e best tooth contact. They must be repIacecI as a set.
.Visually inspect the tapered roller bearings for abrasion, colm change,
or other damagle.
* If there is any doubt as to the condition of a bearing, replace the
bearing housing and the bearings as a set.
• Be sure to check and adjust the pinion gea,r bearing preload and the
bevel gear backlash and tooth contact, when any of the
backlash-related parts are replaced (see Front Final Bevel Gear
Adjustment) .
o When the pinion gear slotted nut is loosened, even if the purpose is
not to replace the parts, check and adjust the bearing prel'oad .
• Fit the toothed washer claw [A] inllO the shaft.
• Apply an oil to the threads and seating surface of the pinion gear
slotted Inut, and tighten it.
Torque - PInion Gear·SIoIIed Nut: 120 N-m (12.0 kg-m," fl.1b)
*If none of the toothed washer tabs [B) align, tighten the nut further
just enough to align one of the tabs with a slot [C] in the nul
• B·end the tab over the nut.
11-1,0 FINAL DRIVE

Front Final Bevel Gear Adjustment F010r

In oroer to prevent one gear from moving away from the other gear Front Final Bevel Gear
under load, the tapered TOner bearings must be properly :preloaclecl. Also Adjustment Procedure
the bactlash(distance one gear will move back and forth without
'mov,ing the other gear) and IIOoIh contact paIIarn of the bevelgea!rs must
be correct to prevent the gears from mailti;ng noise and being damaged.
Above three adjustments are of crit,ical importance and must be carried
out following the correct sequence and method•
• When anyone ,of the backlash-related parts are replaced or the P!nion
I Preload the pinion gear bea.ring.
I
gear nut is loosened; even if the pur;poseis not to replace the parts,
check and adjust the bearilng preload, the bevel gear backlash. and II
tooth contact by replacing shims. .
• The amount of backlash is influenced by the ring gear position more I Adjust gear backlash. I
than by the pinion gear position .
• Tooth contact location is influenced by pinion gear position more than
by ring gear position.
I Adjust too,th contact pattern. I
I Assemble the.fina,,1 gear case comPletelv·1

Bearing Preload Adjustment:

.Check and adjust the bearing .PNIoad in the following cases.
o When any of the parts listed below are replaced with new ones.
Pinion Gear
CoUar
Shim
Tapered RoUer Bearings
Pinion Gear Bearing Housing [AJ
Oil Seal Collar
OWhen the pinion gear slotted nut [B] is loosened; even if the nut is
not removed .
• I'nstall the pinion gear bearing housing and tighten the pinion gear
slotted nut to the specified torque (see Pinion Gear Unit
DisassemblylAssembly) .
• 00 not install the oil seal [C] and O-rings, and do not lock the washer
until the correct bearing preload is obtained.

To alart w,lIII, choo8e a aNm or collar solhal 1M bearings are just

SNUG wIIh NO play but also wIIh NO preload.
Aft 0'I'8I"iftI0ad on .... beerIngs caulddamaga Ihe bearings.

.Apply specified gear oil to the bearings, and tum the gears more than
5 turns to anow the bearings to seat
• Measure the bearing preload. Bearing preload is the rorce
or torque
which is needed to start the gear shaft tuming.
NOTE
OPreload can be measuredeithef with a spling scale 01 a beam-type
torque wlellch. When measured with a spring scale, the preload is
designated by force (N. kg), and when measured with a .torqu,e
wrench, it is designated by torque (N·m, kg-m, in-Ib).
 FINAL DRIVE 11-11

Front Final, Gear Case (Ba,eldash-Related Parts)

Shims for Preload Adjustment

Thickness (mm) Part Number
11.7.0 92025-1072
1.72 92.025-1.073

< Front
1.74
',.76 (primary)
1.78
1.80
92.025-1.074
92.025-1.075
92.025-1.076
92.025-1.077

Ring Gear Shims Backlash Adjustmel1t ;Pinion Gear Shims for Tooth Contact Adjustment

Thickness (mm) Part Number I Thickness (mm) Part Number 1

.0.1 92.025-185.0 .0.1 92.025-1919
.0.15 92.025-1851 .0.15 9'2.025-192.0
.0.5 92.025-1856
.0.5 92025-1921
.0.8 92.025-1857
.0.8 92.025-1922
1.0 (primary)
1.0 (primary)

~
92025-1849
1.2
92.025-1923
92.025-1924 I
Collar f,or Preload Adjustmel1t 1. R.ing Gear Cover
2. Front Final Gear Case
Thil:knEISS (mm) Part Number 3. Ring Gear
10.2 4. Ring Gear Shims for Backlash Adjustment
92.027 -1' 4.01
5. Left Differentilal, Cap
1.0.3 92.027·14.02
6. Ball Bearing
1.0.4 92.027-14.03
10.5 92.027·14.04 7. Co~ar for Preload Adjustment (affects preload only)
10.6 92.027-14.05 8. Shims for Preload Adjus,tment (a,ffects preload only)
110..7 (primary) 92.027-14.06 9. Pinion Gear Shims fOr Tooth Conta.ct Adjustment
10. Right Differential Cap
1.0.8 92.027-1407
11. Pinion Gear
1.0.9 92.027-14.08
12. Tapered R,olle,r Bearing
11.0 92.027-14.09
13. Pinion Gear ~earing Housing
11.1 92.027-141.0
14. Tapered Roller Bearing: (a,ffcects prelload only)
111.2 92.027-1411
15. Oil Seal CoUar (affects preload only)
16. Pinion Gear Slotted Nut (affects preload onlY)'
11-12 FI.'NAL DRIVE

*'1 the preload is out of the specified range,.·replaoe thecoUar and/or

shim(s).
OTo increase preload, decrease the size of the shim(s}or colllar. To
decrease p.reload, increase the size of the shim(s) or conar.
o Change the thickness a little ata time.
eR'echeck the bea~i.ng preload, and readjllst as necessary.

• MeaSure the bearing preload using a spring scale.

Using SprIng.ScaIe:
PInion Gear BearIng Preload :1.5 -3.0. N(0.15- 0.30 kg)
o Hook the spring scale [A] on the handle at a point 200 mm [B]apart
from the center of the gear shaft. Hold the bearing housing in a vise
so that the gear shaft is vertical.
o Apply force to the handle horizontally and at a rightangle to it
SpacIal Tool -PInIGa Gear Holder. 57001·1281 [e]

e Measure the bearingl preload using a torque wrench \[0] •

UsIng Torque WrencI1 :

PInion Gear BearIng Preload T~ : 0.3 - 0.8 Nom (Om
- 0.06 kg-m. 2.6 - 5.21n-1b)
SpacIal Tool - PinIOn Gear Holder. 57001-12811 reI

Backlash Adjustment:
eCheck and adjust the gear backlash when any of the backlash-related
parts are replaced wilth new ones.
eClean any dirt and oil off the bevel gear teeth.
eAssemble the front final gear case (see Front Final Gear Case
Assembly). 00 not install the O-rings during adjustment.
o Check the backlash during tightening of the ring gear cover bolts and
stop tig.htening them immediately if the backlash disappears. Then,
change the ring gear shim to a thinner one .
eSet up a dial gauge against a .ril'lg gear tooth to check gear backlash
shown.
eTo measure the backlash, move the I,eftfront axle {ring g,ear side} back
and forth while hokfing the pinion gear steady. The difference
between the highest and the lowest gauge reading is the amount of
backlash.
*',fthe bacldash is not within the limit replace the ring gear shims. To
increase backlash, decrease the thickness of the shim (s). To decrease
backlash, increase the thickness of the shim(s).
o Change the thickness a little at al time.
eRecheck the backlash, and readjust as necessary.
 FINAL DRIVE 11,·13·

• Move the front axle back and forth [A]

Special Tool- Pinion Gear Holder: 57001-1285 [B]

Dial Gauge [el

Special Tool - Dail Gauge Holder: 57001·1049 [D]

Flna'i Bevel Gear BaCklash

Standard: 0.D9 - 0.20 mm(at ring gear 1OoIh)

Tooth Contact Adjustment:

• Clean any dirt and oil off the bevel gear teeth .
• Apply checking compound to 4 or 5 teeth on the pinion gear.
NOTE
OApply checldng compound to the teeth in a thin, even coat with a
fairly stiff paint brush If painted too thicldy. the exact tooth pattern
may not appear.
o The checking compound must be smooth and firm, with the
consisten'cy of tooth paste.
OSpecial compounds are available from automotive supply stores for
the purpose of checking differential gear tooth patterns and contact.
Use one of these for checking the bevel gears.
• Assemble the front final gear case (see F.ront Final Gear case
Assembly).. Do not install the D-rings during adjustment
.Tum the pinion gear shaft [A] for one revolution in the drive and
reverse (coast) di'rection. while creating a drag on the ring gear.
o Use the pinion gear holder [Bland the left front axle.
SpecIal Tool - Pinion Gear Holder: 57OO1i·1I281
• Remove the ning gear and pinion g;ear unit to check the dlrive pattern
and coast pattern of the bevel g:ear teeth.
OThe tooth contact patterns of both (drive and co.as;t)· sides should be
centrally :Iocated between the top and bottom of the tooth. The drive
pattern can be a linlecloser to thettle and the coast pattern can bea
somewhat longer and closer to the toe.
*11.f the tooth contact pattern is incorrect, replace the pinion gear
shim (s):, fan owing the examp!l:es shown .
• Then erase the tooth contact patterns and check them again. Also
check the backlash every time the shim(s)are replaced. Repeat the
shim change proceclureas necessary.
NOTE
o If the backlash is out of the standard range after changing the pinion
gear shim(s), change the ring gear shim(s) to CO"ect the backlash
before checkin:g the tooth contactpa.ttern.
11-14 FINALD'RIVE

Correct Tooth Contact Pattern

A. Bottom
B.Top
C.Heei
D. Toe

I _.-----.
---t'E--- _______

Incoflrect Tooth Contact Pa!tterns

Example 1: Decrease the thickness of the pinion gearshim(s) by 0.05 mm to correct the pattern shown below. Repeat
in 0.05 mmsteps if necessary.

A. Bottom
. B. Top
C.Heel
D.Toe

~----'
, '---- ---+--

Example 2: Increase the thickness of the pinion gear shim(s) by 0.'05 mm to correct the pattern shown below. Repeat in
0.05 mm steps if necessary.

A.Bottom
B.Top
C.HeeI
D.Toe

1 __ - - - - - - .

~~
 FINAL DRIVE 11-15

Bevel Gear Inspection

.Visually check the bevel gears (Al for sco~ring, chipping, or other
damag.e.
* Replace the bevel gears as a set if either giear is damaged.

Diffe/et1tiaJ Gear Inspection

.Visually check the differential gears [A] for scoring" chipping, or other
damage.
• AIso, inspect the differential pinion gear shaft [8] and gear housing
[C] where the differential gealS rub.
*If they are scored, discolored, or otherwise damaged, replace them as
a set.

Tapered RoHer Bearing Inspection

.Visually inspect the bearings [A] for abrasion; color change, or other
damage.
* If there is any doubt as to the condition of a bearing, replace it.

Ball Bearing Inspection

.Tum each bearing back and forth while checking for roughness or
binding.
*If roughness or binding is found; replace the bearing.

Oil Sea/Inspection
seal.
.VlSually irlSpact the oil
*Replace it if the lips are misshapen, discolored (indicating that the
rubber Itas deterio~), hardened, or been otherwise damaged.
11·16 FI,NAL DRIVE
Bevel Gear Case (KAF620A)

Bevel Gear Case Removal

• Remove:
Transmission Oil (drain)
Cargo Bed
'Propeller Shafts
IBevei Gear Case Bolts [A]
Bevel Gear Case [8]

Bevel Gear Case Installation

eCheck and adjust the bevel gear backlash and tooth contact when any
of the bacldash-related pa,11S are replaced (see Bevel Gealr .Adjust-
ment).
eCheck to see th,at the bevel gear case knock pin [A] is in place.
.Torque:
Tarque - Bevel Gear Case Bolls: 22 tHn (2.2 kg-m, 11.0 "'Ib)

Bevel Gear Case Disassembly

• Remow:
Holder Nuts [A]
Holder [B]

.If the driven gear assertIbly is to be disassembled, loosen the housing

locimut [A].
SpecIal Tool ;,.. SoCket Wrenc:Ir. 57001-1383 [8]
Pinion Gear Holder: 57001·1281 rC]

• Remove:
Driven Gear Assembly [A]
Driven Gear Shim(s} [8]
 FINAL DRIVE 11-17

• Remove:
Hous.ing Locknut
Bearing Housing [A]
Special Tool - Socket Wrench: 57CI01-1363 [8]
Pinion Gear HOlder: 57001-1281 [e]

• Remove:
DriYen Gear Shaft Nut [A]
SpecIal Tool - Pinion Gear Hoider:57U01-1281 [8]
o Pressing the spring seat [C], remove the driven gear shaft nut.

• Remove:
Bearing Holder [A]
Special Tool - Hexagon Wrench,. Hex 40: 57801-1. (I]
• Remove:
Ball Bearings
SpecIa.ITooi - OU Seal & Baarfng Remover: 57801-1'0S8
Bearing DrIVer Sat 57801 ..1129

Bevel Gear Case Assembly

.Install the housing locknut [Al so that the chamfered side ra1 faces
to the bearing •
• ApplY non:permanent Jocking agent
Driven Gear Shaft Nut
Bearing Holder
Housing L.oclmut
.TOJque:
T~- Driven Gear Shalt Nut 110 N-m(11.o kg-m, • M)
Bearing Hotder: 120N-m (12.0 icg-m., 87 ft-Ib)
HOIBlngi Lodcnat: 120 N-m (12.0 kg-m,rT ft.."
• Grease:
HoJder Oil Seal Ups
111-18 FINAL DRIVE

Drive Bevel Gear Removal

.Remove:
Hi/Low Gear Case
Drive Gear Nut [A]
Drive Gear [B]
Drive Gear Shim(s) [C]
Drive Gear Shaft [0]
Spacial Tool - TI'BMIRIssion Gear Holder: 57801·1384 [E]

Drive Bevel Gear Installation

.Check and adjust the bevel gear backlash and tooth contact when any
of the backlash-related· parts arerepiaced (see Bevel Gear Adjust-
ment) .
• AppIy oil:
Drive Gear Nut Seating Surface
Torque - DrIve Gear Nut 120 N-m (12.Gkg-m, . , ft.I)t

Bevel Gear AdjusfmtfJnt

·'n order to prev,ent one gear from moving away from the other gear Bevel Gear Adjustment procedure
under load, the backlash and tooth contact pattam of the bevel
gears mU$t be conect to prevent the gears from making noise and being
damaged.
When replacing anyone of the backlash-related parts, be sure to
check and adjust the backlash and tooth contact First adjust the
baddash, and then tooth contact by replaci.ng shims.
These two adjustments are of critical importance and must be carried
out in the COi1'eCt sequence, using the procedures shown.
.1 Assent I etl:!le bevel oear 8SSElI'Itl1 Y caI'Cll ete I Y.

.Backlash .AdjUsbrl8l1t:
.Check and adjust the gear backlash when any of the backlash-related
parts are replaced with new ones.
• Install the drive gear with the prima~ry shim'andassemble the driVen
gear with .the primary shim. Do not install! the bevel gear case ho,lder
during adjustment.
• Clean any dirt and oil off the bevel gear teeth .
• llnstali the bevel gear case and tighten the case bolts.
o Check the backlash while tightening the case bolts. Stop tightening
them immediatetvif the backlash disappeairsand change the shim to a
thinner one.
 FllNAt DRI:VE 11-19

.Set up a di,all gauge [A] against one ot the grooves in the I.ocknut
[8] .
• To measur,e the backlash, tum the sha'ft clockwise and counterclock-
wise while holding the drive bevel '9'ear s.teady. The difference
between the highest and lowest gauge readings is the amount of
backlash.
Special Too/ - Transmission Gear Holder: 5700't-1384 [C]
*If the bacldash is not within the limit,. replace the shim(s) at the drive
and/or driven gear. To i,norease backlash, decrease the thickness of the
shim(s). To decrease backlash, increase the thickness of the shim(s).
*Change the thickness a little at a time.
• Recheck the backlash, and readjust as necessary.

Bevel Gear Backlash

Slandard: 0•• - 0~18mm (at housing locknut groove)

.,eveiI G_r Case .<IBa,cklash-Related Parts)

11. Driven Gear Shaftl
2. Beariing Housing ,I
3. Driven Gear Shim s)
4. Bevel Gear Case I
5. IBalil. Bearing ,
6. 'Driven Bevel Gea~
7. Hi/Low Gear cas,
8. Drive Gear Shaft I
9. Ball Bearing i
10. Drive Gear Shim't)
11. Gasket i
12. Drive Bevel Gear!
i
orhleil'l'Gear Shims ()
I 3 !
Thiclmess.[mm I Part Number
0.1 92025-1859
0.15 92025-18'60
0.5 92025-1861
0.8 92025-1862
1.0(primary) i92025-1858
i 1.2 I 192025-1863
Drive Gear Shims (10)
Thiickness(mm) 1Part Number
0.15 I 192025-11573
0.2 192025-11"574
0.7 192025-1534

0.8 92025·1535
0.9 92025-1536
1.0(primary) 92025-1537
1.1 92025-1575
11.2 192025-1538
1.3 1920.25-1533
11-20 FINAL DRIVE

Tooth Contact Adjustment:

.Clean any dirt and oil ,off the bevel gear teeth .
• Apply checking compound to 4 or 5 teeth on the driven bevel gear.
NOTE
OApp/y checking compound to the teeth in a thin, even coat with a
~irIy stiff paint brush. If painted too thickly, the exact tooth pattern
may not appear.
o The checking compound must be smooth and firm with the
consistency of tooth pasI8.
oSpecial compounds are available from automotive supply stores for
the purpose of checking differential geat tooth pattems and contact.
Use this for checking the bevel gears.
• Tum the driven bevel gear for 3 or 4 turns in the drive and reverse
(coast) directions, while creating a drag on the drive bevel gear.
• Check the drive pattern and coast pattern. of the bevel gear teeth. The
tooth contact patternS of both drive and coast sides should be centrally
located between the top and bottom of the tooth, and a little closer to
the toe of the tooth.
*If the tooth contact pattem is incorrect,. lreplace theshim(s) at the drive
bevel gear and shim(s) at the driven bevel gear, following the examples
shown. Then erase the tooth contact patterns, and check them again.
Also check the backlash every time the shims are replaced. .Repeat the
shim change procedure as necessary.
NOTE
Off the ba.ckJash is out of the standard range alter ch8nging shims,
correct the backlash before checking the tooth contact pattern.

A Drive Bevel Gear

B. Driven Bevel Gear
C. Bottom
O.Top
E. Heel
F.Toe

Incon'8l:t Tooth Contact Patterns:

Example 1: 'Increase the thickness of the drive bevel gear shim(s) by
O.05mm, and/or increase the thickness of the driven bevel gearshim(s)
by O.95mm to correct the pattern shown below. Repeat in O.05mm steps
if necessary.
A Drive Bevel Gear
B. Driven Bevel Gear
C.Bottom
O.Top
E.Heet
F.Toe
, , . @

-7Y _J4,® .
I

cr®
r§AN-®
(i('~
 FINAL DRIVE 11·21

Example 2: Decrease the thickness of the drive bevel gear shim(s) by

O'.06mm, and/or ctecreasethe thiCkness of the driven bevel gear shim(s)
bV'O.05mm ·lOconectthep.atlal'n shown below. Repeat in O.05mm steps
if necessary.
A !Drive 'Bevel Gear
B. Driven Bevel Gear
C. B,ottom
D.Top,
E. Heel
F.Toe

-+---,*'k
'l<:
Bevel Gear InsptJCIirt;JiI
.Visuall¥ check the bevelgealS [A]b' scaring, chipping, O¥ other
damage.
* Repla4:e the bevel gears as a set if either gear is damaged.

BaIIB.,injJ Inspectkm
.Si,l'lC8 the· ball bearings 8N1made to extremelly close tolerances, the
wear must be judged by IeeIlIther than measurement Clean each
bearing iin, high flash~point SOlVent. dry it (do not spin the bearing
while ,it is drY), amd oint with engine oil.
.Spin the bearing by I1tand to. check its condition.
*'If the bearing is noisy, does not spin smoothly,or haS any rough spots,
replace it

Oil Sea/Inspection
• Inspect the oil seals.
*rubber
Replace it if the lips are misshapen,. discolored (indicating that the
has deteriorated), haR:tened,or been otheI'Wise damaged.

Damper Inspectkm
.Visually ir!spectthe driven, bevel gear [AJ. cam follower [8], spring
[Cl, and shaft [D].
* Replace any ,part that appears damaged.
11-22 FINAL DRIVE
Propeller Shafts (KAF62OA)

Propeller Shalt .Removal

• Remove:
Propeller Shaft Bearing Hous'ing Mounting Botts [A1 and Nuts
Propeller Shaft Bearing Housing [B]
Propeller Shafts [e]

Propeller Shaft .Installation

.Wipe the old grease off the splines of the propeller shafts,. and grease
to them.
•.Inspect the propeller shafts.
• Replace the tape [A) (PIN 39188·1052) on the front pinion gear if it
is damaged.
o If the front propeller shaft [BJ can not be installed on the tape, cut. the
tape off about 35 mm to decrease the thickness of the tapes.
• Apply grease to the outside of the tape.
• Install the front propeller shaft [8] on the front pinion gear.
• Install the rear propeller shaft. [C] on the rear driven gear shaft.
• Install the I188r propeller shaft front end [0] on the front propeller shaft;
rear end [E]. align,ing the yoke angles of the front and rear pro.peller
shafts [Fl .
• ParaUel [GJ the propeller shaft bearing housing [H] with the mounting
bracket [I], and tighten the mounting bolts and n.u1tS.
o Make the 3 mm clearance [JJ between the front propeller shaft and the .
front pini(m gear nut [K].
 FI:NAl DRIVE 11-23

Propeller Shaft Inspection

• Visually inspect the splines of the propeller shafts.
*If they are twisted, badly wom, or chipped, replace the shafts.
• Check that the universal joint works smoothly without ratting or
stiicking.
*.If it does not the bearings of tile Joint are damaged. Replace the
Ipropeller shaft with a new ooe.
11-24 FINAL DRIVE
Drive Shafts and Axles

Front Drive Shaft and Axle Removal (KAF62OA)

eRemove:
Steering Knuckle
Rubber Band [Al
Axle [B]
o Slide the d.ust boot [C] from the drive shaft [D] and pullout the axle.

eRemove:
Drive Shaft Cap Bolts [A]
Drive Shaft [8] and Cap [C]

Front Drive Shaft and Axle Installation (KAF62OA)

eWipe the old grease off the splines of the drive shaft, aXle, and cap oil
seal, and grease them.
elnspect the drive shaft and axle.
eBe sure to install the spacer in the recess of the front final gear case.
eTorque:
Torque - DrIve'" cap 80lil: 8.8 N-m (0.10 kg-m, 78 .....)
elf the dust boot was removed, iinstall it on the axle so that the small
hole [A] in the boot is toward the axle side.

Rear Drive Shaft and Axle Removal

eRemove:
Rear Wheels
Rear Brake Drums
Rear Brake Panel Assemblies (with Brake Pipes and Hoses)
Leaf Springs
Rubber Bands (A]
Axles [B] and Axle Bracket [C]
o Slide the dust boots [0] from the drive shafts [El, and pull the one of
the axles from the drive shaft, and then the other axle from the shaft.
 FINAt DRIIVE 11-25

eRemove:
Drive Shaft Cap Bolts [A]
Drive Shaft [BJand Cap [C]
O$et the differentia& shift lever into the UN-LOCK position.

Rear Drive Shaft and Axle Installation

.Wipe the old glre8S8 off the splines of the drive shafts. axles, and cap
oil seals, and grease them .
• Inspect the drive shafts and axles.
• Align the yoke angles of the drive shaft and axle.

elf the dust boot was removed. install it on the axle so that the small
hole [Alin the boot is toward the axle side•
•.Adjust
Transmission Oil

Drive Shaft and Axle Inspection

.Visually inspect the splines of the drive shaft and axle.
*'If thayar,e twisted. badly worn, o.r chipped, replace the dr:ive shaft
and/or axle with a new one.
• Check that the univet'Sa1 joint and/or ball joint works smoothly without
rattling or sticking.
*If it does not,. the bearings of the joint are damaged. Replace the drive
shaft and/or axle with a new one.

Dust .Boot Inspection

eVisuaUy inspect the bootes) in accordance with the Periodic Mainte-
nance Chart or if the drive shafts 'or ailCles are noisy during operati.on.
* If the dust boot is tom, worn,. deteriorated, or lea,ksgrease, replace it.
NOTE
o The front axle dust boot [A] is part of the axle. Axle replacement is
necessary to replace the boot
11-26 FINAL DRIVE

Ball Bearing Inspection

.Tum each bearing back and forth while checking for roughness or
binding.
*If roughness or binding is found, replace the bearing.
• Examine the bearing seel for teats or leakage.
*If the seal is tom oris leaking, replace the bearing.

GteaSe Sea//fIS{J8CIion
.VISUaIIy inspect the grease seals.
* Replace if the lips are misshapen, discolored (indicating that the rubber
has deteriorated), hatdened, or been otherwise damage.
 BRAKES 12-1

Table of Contents

Exploded View ................. "'''' .....................................................................................12-2

Specifi:cations ................... "''''............ "........................."....."....... '''................... "..............12-4
Brake Fluid .........................""...................................."...."................................"..........12-5
Brake Fluid Recommendation ...................""........."................ "................"..............12-5
Brake Fluid Leveli Inspection .........".................................... "."........ "........... "..........12·5
Brake Fluid Changing .. "."................"....................."..................".......................".......1.2-6
Brake Line Air Bleeding ................ "" ...............................................................".. "........1.2-7
,Brak.e Pedal. and Master Cylinder ..... "" .......................................,." .............................12-8
Brake Pedal Free PI:ay Adjusbnent ..........................."..................,............. "...........1.2-8
Master Cylinder Removal ....... :.....,...,... "............... "................. "......,."................. ".....12-8
Master Cylinder InstaUation ................ "............... "..........................".......,....""" .......12-9
Master Cylinder Disassembly' ............................."........"................. "......................12-9,
Master Cylinder Assembly ...................................................................................12-10
Master Cylinder Inspection ...................... ;.........................................................12-10
Brake Hoses and Pipes ...........................................................................................12-11
Brake Hose and Pipe l,nSpection ................... ".....................................................12-11
Brake Hose and Pipe Replacement....................................................................12-11
Brake :Drums..............................."..........,........................,..................... "...".................,.12-12
Brake Drum R,emoval., ........................................................"...............................12-12
Brake Dru'm Insta.llatiion ..............................................................."...................... 12-12
Brake Drum Wear ..............................................................................................,,12-13
Brake Panel Assemblies ........................................................".................................12-14
Brake Panel R:emova:I .........:..............................................................................,,12-14
Brake Panel Installation ...................,...................................."....... "... ,................... ",12-15
Wheel Cylinder Assembly ... "."" ... ,." .....".... "..........................,.................................,,12-16
Wheel Cylinder Inspection .,.. ,., .... "" .......... "......."..................,...'........ '....".................,,12-16
Brake Shoe Lining, Wear....... "" ....".......... "............................."..............................12-17
Brake Shoe Spring Inspection .....'......... ,...... "., ................... "." ........ "........................12-17
Parking Brake Lever and Cables .............................................."....... ,.................... ".,,'12-18
Parking Brake Lever Travel .Adjustm.ent ................................................................12-18
Parking Brake Cable Lubrication .............................................................................12-18
Parking Brake Cable Inspection ..................................................."...................... 12-18
12-2 BRAKES
Exploded View

AD : AppIy ......Ive.agent.
F : Apply brake fluid.
G:Applyg.......

Tt : 5;9 N-m(O.80kg-m, 52 1...1b)

12: 7.8 Nom (0.80 kg-m, 81 In-Ib)
13: L8 N.... (O.90kg-m, 78 11Mb)
T4: 18 N-m (1.8 kg-m, 13.0 ft.Ib)
15 :25 N-m(2.5kg-m,.18.D ft.Ib)
TI: 44N-m (4.1 kg-m, 33 ft.Ib)
T7: 195N-m (20.0 kg-m, 145...,)

K~"
 BRAKES 12-3

White

KAF620A
12-4 BRAKES
Specifications

Item Standa.rd Service limit

I
Brake Fluid:
Type D.O.T.3 - - -
Bnmd Atlas Extra Heavy Duty - --
I Shell Super Heavy Duty - --
Texaco Super Heavy Duty - --
Wagner Locikheed Heavy Duty ! - --
I
Castrol Girling-Uni1versal -, - -
i
, Castrol GT (LMA) ,
- --
Castrol Disc Brake Fluid - - -
Fluid level Between upper and lower level lines - --
Brake Pedal:

,
Brake pedal free play 5 -10 mm I - --
!
Brake Drums: i

Brake drum inside diameter 180.000 - 180.160 mm 180.75 mm

Brake Panel Assemblies:
i
Brake shoe lining thickness 4.5mm 1.0mm

Parking Brake Lev8lr:

Parking. brake .Iever travel 8 -12 notches (clicks) at 200 N (20 kg, 44 lb)
I
I -. --
SpecIal Tool - inside Clrellp PIIerI:mJ01-143
RGIoI' Puller,. M16JM181M2O/M22 x 1.5: 57081-1216
Bra.e IDrum Remover: 57001-1260
Brake Drum'Pusher: 57001-1281
Brake Drum Hofder:. 57001-1325
Brake Drum Remover Nuts: 57G01-1326
 BRAKES 12-5
Brake Fluid

Brake Fluid Recommendation

Recommended fluids are given in the table below. If none of the
recommended tluidsare availabl.e, use extra heavy-duty brake fluid only
trom a container marked 0.0.T.3.
Recommended B'rake Flakl
Type: D.0.T.3
Brand: Atlas Extra Heavy Duly
Shell Super Heavy Duly
Texaco Super Heavy Duly
Wagner LocIcheecI Heavy DUly
castroI Glrlmg.onlveraal
CasIroI GT (LMA)
CasIroI Disc B.... fluid

nWARNING

Never ....... old brake ftuld.

Do Il0l ... fluid from • COIdatner Ihat hal bien left unaeaIed orlhal:
has 'been open lor a .Iong lime.
Do IlOl mbc In types and . . . . . oil ftuId lor ... In the brake. This
. lowers the. brake fluid boil. . poInI and could cause the brake to !'

InaI8ctIve. • mil)' also cauae the rubber brake paris 10 deIerIorate.

Don't leave the I'888f'IOIr cap ,. for any IengIh oil time to avoid
moisture canlamfnatlan of the .1eI.
Don"tadd or cfIange lie fluid In lheraln ar when a SIrOng wind Is
blowing.
• .,., oil the brake line fillings or the bleed valve Is opened'" any
lime, the AIR MUST BE BlED FROM THE BRAKE.

CAUTION
Brake aald qulcll:ly ruins paJrdad surIaceI; any spilled lIuld ....Id be
camplletelywlpe up Immecllalely.

Brake Fluid Level Inspection

.With the vehicle on level ground, check that through the inspection
hole [AI, the fluid level in the reservoir is between the upper (MAX)
and lower (MIN) level lines [8].
*If the fluid level is lower than the lower level line, check for fluid leaks
in the brake lines, and fill tile reservoir to tile upper level line.

i .. WARNING
Change the fluid In the brake sy8tem completely • Ihe fIu,1d level Is
low bid lie Iypeand brand of the fluid already In, the .....rvoIr are
UMnown.

• Remove the maintenance cover [C) .

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

i-..WARNING
! Rille brake pedal has a sol or "spongy teeIIng". when It Is applied,
Ihero mItIht be air In the brake I..... or . . .,...., "8]( bA dw'aeIIvA.
SInce I Is dangerous to operate the vehicle under such candllons,
have the 'brake sysIam. servlcec:llmmecilialely.
12-6 B,RAKES

Brake Fluid Changing

• Remov,e the maintenance cover.
• Check that there is plenty of fluid in the reservoir.
NOTE
o The fluid level must be checked several times during the fluid
changing and replenished as necessary. If the fluid in the reservoir
runs completely out any time during fluid changing. air bleeding
must be done since air wiD have entered the line.
• Remove the wheel for extra clearance.
• Connect a clear plastic hose to the bleed valve at the wheel cylinder,
ru!nning the other end of the hose into a container.
NOTE
OStart with the rear left or right wheel and finish witht.lle front If!It or
right Wheel.
• Open the bleed valve, apply pressure to the brake pedal, close the valve
while the brake is applied, and then quicklV release th,e pedal. Repeat
this operation until fresh brake fluid comes· out from the plastic hose
or the color of the fluid changes.
1. Open bleed valve.
2 Apply brake pedal and hold it
3. Close bleed valve.
4. Release brake pedal .
• Torque:
Torque- 81eec:1 Valves : 5.9 Nom (0.60 kg-m, 52 In-Ib)
• Repeat the previous step for eaeh wheel .
• When brake fluid changing is finished, add the fluid to the upper level
in the reservoir.
eApply the brake foroefully for a few seconds, and check for fluid
leakage around the fittings.

i.,WARNING
.118 brake pedal has a soft or Waponge ....Ing'" when lila applied,.
. there might be air In lie brake One or lie brake may be dellclive.
SInce 1111 dangeroui.lD operaIe lie vetIIcIe under such condIIIons,
. . . . . . . from ... bnIka line immediately.

elnstall the removed parts.

 BRAKES 12-7

Brake Line Air Bleeding

• Remove the maintenance cover.
• CheCk that there is plenty of fluid ,in the reservoir.
NOTE
o The fluid level must be checked sever:al times during the bleeding
operation and replenished as necessaty. If the fluid in the reservoir
runs completely out any tim.e during .b/eeding~ the bleeding
operation must .be done ovet again from the beginning since air will
have entered the line.
• With the reservoir cap off, slowly pump the brake pedall several times
until no air bubbl,es can be see rising up through the fluid from the
holes at the bottom of the reservoir. This bleeds t!he air from the master
cylinder end of the line.
• Remove the wheel for extra clearance.
.Connect a clear plastic hose to the bleed valve at the wheel cylinder,
running the other end of the hoSe j,nto a container.
NOTE
OStJilrt with the rear left or right wheel and finish with the front left or
right wheel.
• Pump the brake pedal a few times until it becomes hard to pump. Hold
the peelal in the down position.. Quickly open (tum counterclockwise)
and close the bleed valve. Then release the pedal. R,epeat this
operation until no more air can be seen coming out ;into the pl.astic
hose.
1. Hold brake peelal applied.
2. Quicldyopen and close bleed valve..
3. Release brake pedal.
.Torque:
Torque - Bleed Valves: 5.9 N-m (O.80kg-m, 52 ,In-Ib)
• Repeat the previo:us st~ for each wheet
.When air bl,eeding is finished, add fluid up to the upper level in the
reservoir.
• Apply the brake forcefully for a few seconds, and check for fluid
leakage around the fittings.
.'nstall the removed parts.
12-8 BR.AKES
Brake Pedal and Master Cylinder

Brake Pedal Free' Play Adjustment

.Check brake pedal free play [A].
Brake Pedal Free Play
Standard: 5 -10 mm
*If freeplay is not correct, adjust it.
• 'Loosen the locknut [B] and tum the push rod [C] to obtain the correct
amount of free play.
• Torque:
TOI'qIIIe - Push RodLoclmut: 18 N-m (1..8 kg.m,13.0 1·1b)
.Check for brake drag and bra'king effectiveness.

Incorred: adjustment will InIuIIIcIent free play can cause brake

healing and drag. Skidding and lass or control mBJ result.

Master Cylinder Removal

• Remove:
Front Fender upper
Brake Bose Banjo Bolts [Al
Brake Pipe Nipple [B] (unsCJeW)
• Immediately wipe up any bra!ke fI!uid that spills.

CAUT10N

com.....,
Brake fhlid quickly ruins !palnleci SlUface8j 8", spilled ftg,1d should be
wfped up, Immedlataly•

• 'Remove:
.Master Cylinder Mounting Bolts [C]
Master Cylinder [0]
 BRAKES 12-9

Master Cylinder Installation

• Use a new flat washer on ,each side of the brake hose fittiil1g, .
• Apply brake fluid:
Brake Pipe Nipple Threads
.Torque:
Torque - Brake Hose Banjo _Bolls: 25 N-m (2.5 kg-m, 18.0 ....,)
Brake Pipe Nipple: 118 N-m (1.8 kg-m,13.0ft.1b)
.,Bleed the brake I!ine after master cylinder installation.
• Adjust
Brake Pedal Free Play Adjustment
.Check that the brake line has proper fluid pressure and no fluid
leakage.

Master Cylinder Disassembly

• Push the pistons in all the way with a screWdriver and remow the
paon stop bolt
• Remo've the retainer with thecirclip pliers and remove the pistons.
SpeclalTooi - inside Qrclip Pllera: 57001-143
o Remo,ve the pistons by lightly applying compressad air to where the
brake pipe fits into the cylinder.
Dust Cover [Al
Retainer [B]
Pistol'ls [C]
Spril'lgs [D]
Seoondary Cup [E]
Primary Cup [F]
Piston Stop Bolt [13]
Master CyHnder [H]
Be careful of the secondary cup direction [I].
12-10 BRAKES

Master Cylinder Assembly

• Before assembly, clean all parts inc1luding the master cylinder with
brake fluid or alcohol, and apply brake fluid to the removed parts and
the inner wall of the cylinder.

Use only brake fluid, isopropyl alcohol, or ethYl alcohol, for cteanlngi
brakepel1S.Donot .... ~0Iher fluid for c/eanllng these paris.
GasolIne, moIOroH, or ~ oItIer peIroIeum dislilialle wUl cause
deIerJoratIon of Ihe rubber parts. 011 spilled on any part will be
"1 dllllcull to wash 01 compIeIely, and will evenlUally delerloralle the
rubber uaedln Ihe brake•

• Push the pistons iln all the way with a screwdriver and install the piston
stop bolt.
• .Torque:
Torque - Piston Slop Bolt: 8.8 N-m (OJIO kg-m, 78 11Mb)
Reservoir Clamp Bolt: 5.9 Nom (0'.80 ka-m, 52 In-Ib)

Master Cylinder Inspection

.Check that there are no scratches, rust or pitting on the
inside of the
cylinder and on the oU1Side of the piston.
*If the cylinder or piston shows any damage, replace them .
• Inspect the primary cups and secondary cups.,
*If a cup is wom, damaged, softened (rotted), or swollen, replace it
*If,fluid leakage is noted at the brake push rod, the secondary cup of the
rear piston should be replaced•
• Check the dust cover for damage.
* If it is damaged, replace it.
• Check that the relief and supply ports are not plugged.
*If the smal'l relief port Pecomes plugged, the brake shoes will drag on
the drum. 'Blow the ports clean with compressed air.
• Check the piston retum springs fa,f any damage.
*If the spring is damaged, replace it.
 BRAK.ES 12-11:
Brake Hoses and Pipes

Brake Hose and Pipe Inspection'

.The hiigh pressure inside the brake line can cause flluid to leak or the
hose to burst if the Jine is no,t properly maintained. Bend and twist the
rubber hose while exam ill ling it
*Replace it if any cracks or bulges are noticed .
• The metal pipe will rust if the Plating is damaged.
* Replace the pipe if it is rusted, ended (especially check the fittings),
or if the plating, is badly scratdhed.

Brake Hose and Pipe Replacement

.To remove the metal piipes [A],. unscrew the nilpples [B]~
.To JI8IllOVe the hoses [C], remove the banjo bolts [0] andlor pull out
the retainers [E] .
• Immediately wipe up any brake ,fluid that spills.

i Brake Ruld CJlIcIdr ruIns.pU1IacI ufaces; any spllIIId! fluid IIiIouId be

: ~1"11y wiped.... lmmedlalelr•

• Use a new aluminum washer for each side of the hose fittings at the
master cylinder•
• Apply brake fluid:
IBrake pijpe Nipple Threads
.Torque:
Torque - Brake :Haee Banjo Bola : 25N-m, (2.5 kg-m, 18.0 ft.Ib)
Brake ,Pipe NIppteI: 18 N.... (1.8 kg-m, 13.0 ft.Ib)
.,Check that the brake line has proper fluid pressulre and no fluid
lleakage.
12·12 ,BRAKES
Brake Drums

Brake Drum Removal

• Remove:
Wheel
Cotter :Pin
Axle Nut [A]
o Loosen the axle nut while, applying the brake, and release the brake.

• The brake drums (except for the front brake drums on KAF620B)are
press-fitted on the axles. Use the brake drum remover, stud nu1S. and
rotor puller (speciaI1OO1s) to 'remove the drums.
oMount the brake drum remover on the drum studs with the stud nuts
and washers (,parts in the remover ~).
SpecIal Tool - RoIar :PuI...., 11181M1·8IMJOIM22 x 1.5:57001-121" [A]
Brake Drum Remover. S7OO1·121O ['B]
Brake Drum Retnovw Null: 5701'1-1321 [e]
W....... [D]

.Brake Drum Installation

.Observe the folloWing procedure to install the brake drums (except for
the front brake drums on KAF620B).Replace the drum with a new
one if its maximum press-fitting force (torque) is less than the service
limit.

Drum Pre_ tilling Force (Torque)

Service LImit 20 N-m (2.0 kgom, 14.5...."
OAppIy a molybdenum diStJIfide lubricant (grease or oil type, either will
do) to the SlPlines on the drum.
o Mount the brake drum holder (special tool) securely to the drum studs
with the wheel nuts.
o Using th.e bake drum pusher (special tool), drive the drum onto the
axle until the pusher stops.
SpecIal Tool ~ Brake Drum Holder: S7OO1-1325 (A]
Brake Drum Pusher: 57OD1-1261 [I]
o Apply a molybdenum disulfide lubricant (grease or oil type, either will
do) to the threads and the seating face of the axle nut
o Drive the drum further using the axle nut and washer instead of the
pusher until the drum stops. At this time, use a torque wrench to tum
the axle nut Note the driving force (torque) of the nut.
*The drum must be press-fitted on the axle. If the maximum torque for
driving: the nut is less than the service limit, the drum will ;not be tight
enough and must be replaced.
*If the maximum torque for driving the nut is more than the service limit
retighten the nut to the .specified torque.
o Remove the brake drum holder.
 BRAKES 12-13

.Grease [AJ:
Front Brake Drum Grease Seal Lips
.Torque:
Torque - Axle Nut 185 N-m (20.0 kg-m. 145 "Ib)
• Do not press the drum bolts out.
*I~f
a drum bolt is damaged, replace the drum .

Brake Drum Wear

• Measure the inside diameter of the drum alt several poin1S.
*If any measurement is greater than the service limit, replace the drum.
*Ifthe drum is wom unewmlyor SCOlred, lightlly tum the drum on a brake
drum lathe or replace it 0'0 not tum the drum ~nd the service limit
Brake Drum ...... DIIun8Ier
StandanII: 1ao.oao .... 110.180 rmn
Service limit 180.75 mm
12-14 BRAKES
Brake Panel Assemblies

Brake Pane/Removal
• Remove:
Brake Drum
Brake Shoe Springs [A]
Brake Shoes IB]
o Push the shoe hold-down spring [C] and twist the pin [0] to lremove
them.

NOTE
o Hold the brake shoes with a clean cloth to protect the linings from
grease ,or dirt.
• Remove:
Brake Panel Mounting Bohs [E]
Bmke Panel [F]

• Remove the following if the brake 'panel or brake wheel cylinder [Al
,is to be freed from the brake pipe.
Brake IPipe Nipple IB]
o Immediately wipe up any brake fluid that. spi,lls.

ara. ftuld quickly ru,ln8 painted surfaces; any spilled IIuId should be
completely wiped up immediately.,

• Remove the following for the rear brake panel removal.

Cotter Pin [A]
Clevis Pin [8]
Parking Brake Lever Linkage [C]
 BRAKES 12-15

Brake Pane/Installation
.Set the brake shoe clearance adjuster so that the drum can be
re-installed on the panel assembly.
o Front brake; turn one of the wheel cylinder ,ends [A]
while pushing it
in. Keep the other end from turning [B] until both me ends of the
p!istons aire, back in thecylifldercompletely.

o Rear brake; pry the ratchet lever tA] with a screwdriver to reset the
shoe clearance adjuster in its original position [B] .

• AppIy brakeftuid:
Brake Pipe Nipple Threads
.Torque:
Torque - Wllleel CylInder IIoImIIng Bois or Nuts: 7.8 Nom (0.80 kg-m,
IIIn-IbJ
BnIke Panell MountIng BoIs: 44N-m (4.5 kg-m, 33 .....)
BrBe Pipe NWIe: 18 N-m (1.8, kg-m, 113.0 I ...)
.Grease [AJ:
IBrake Panel and Brake Shoe 'Contact Points
Wheel Cylinder Piston Ends
Brake Shoe Anchor Ends
.Grease (rear brake only) [A]:
Shoe Clearance Adjuster Pivots
Shoe Clearance Adjuster and Shoe Contact Points
• Bleed the brake line after drum installation.
• ,Check the brake system 10 be sure there is adequate braking power.
Also ibe sure there is no brake drag, or fluid leakage.

, ""WARNING
Do not .....,.10 drive lie WIhIcI8 until a compIeIe brake .....
mollaR ils obIaInacI by ~ lie brake pedal untIIlhe brake 8hoaII
contacI lie drum, oper8IIng . . ·sIIIoe clearance adlUSlar IBdII brake
shoe 10 br'aH drum contact Is made. The brake willi not fIIncIIonon
lie lralapplleadon, oflhe pedal ilthla Ia noI done •

• Adjust
Parking Bralke Lever T,ravel Adjustment
12-16 BRAKES

Wheel Cylinder Assembly

.Before assembly, clean all parts including the whee! cylinder with
brake fluid or alcohol, and apply brake fluid to the removed parts and
the inner wall of the cylinder.

Use onlybraU 1II1d, lIapIoprIalcohol, or ...,1 alcohol, tor cIMIdng

brake parII. Do not ... .., OIlIer IIuId tar cleaning ..... perIL
GaaoIIne, maIDr oil, or 8ft¥' ,OIlIer peIroIeI.In, dlstlliala will cause
dll.rtoraIIan of lie rubber pertL on .apIIladOR any pelt wID be
dllllculllD ...... off compIeIIIly. andwll eventually deIeriorate the
. rubber uaed Inlhe brake.

Wheel Cylinder Inspection

.Check that there are no scratches, rust or pitting on the inside of the
cylinder and on the 'outside of the p,iston.
*,If the cylinder or piston shows any damage. replace the cylinder.
• Inspect the cups.
*'t a cup is wom, damaged, soften,ed (rotted), or swollen, replace the
cyfinder.
*If fluid leakage is noted at the dust covers. the cylinder should be
replaced to renew the cup.
• Cl:1eck the dust covers for damage.
* If they are damaged. replace the cylinder.
• Check the spring. for any damage.
*If the spring is damaged, replaoethe cylinder.
• Front brake only: Check the brake shoe clearance adjuster for damage.
* If it shows any damage. replace the cylinder.

Dust Cover [AJ

Piston (8]
Cup [C]
Shoe Clearance Adjuster (From)[D]
Spring (Rear) [E]
 BRA,KES 12-17

Brake Shoe Lining Wear

• Measure the lining thickness at several poin1S.
Bnlke Stloe lining ThIciImees
Sllndard: 4.5. mm
ServIce Limit 1.0 mm
*asIf any measurement is less thanl '1iM &elVice, limit replace both shoes
a set.
*Ifbefore
the lining thickness is g.riater than the service limit, do the following
insllalling, the shoes.
.File or sand down any high spoilS on the surface all the lining .
• Use a wire brush to remove any foreign particles from the lining..
• Wash off any oil or g,rease with an oilless solvent

Brake Shoe Spring Inspection

.Visually inspect the brake shoesplings [A] for breaks or distortion.
*11 the springs are damaged in any way. replace them.
12-18 BRAKES
Parking Brake Lever and Cables

Patking Brake Lever Tra~e/ Adjustment

.Check parking brake lever travel [AJ.
C Pull the parking brake lever upward slowly aU way. Count the number
of notches (cl'icks) during lever travel.
* If lever travel is notcorrect..adjust it.

Park..,g Brake Lenr Travel

Standard: 8 - 1.211101ches (cllcb) at 200 N (20 kg, 44 Ib)
• Release the parking brake and return the lever to its rest position •
• Loosen the locknut riB] and tum the adjusting nut [C]IO obtain the
correct amount of lever travel.
• Tighten the locknut.
• Check for brake drag and braking effectiveness.

IIncoITect adfustmenI will In8ufIIclenl:he Iplay can cause ...... 10

0Y8I'heat and drag. Skidding ancIloes aCconIrOI mar rMUlL

NOTE.
o If the parking brake leVfJl'travei cannot be adjusted by using the
adjusting nut at the lever, use the adjusters [A] at the parking brake
levtJf and rear wheels. 00 not forget to adjust both the left and right
cables evenly, and then StJCIire!y tjghten the adjuster mounting nuts
[8].

Parking Brake Cable Lubrication

Whenever the parking brake cables are removed, lubricate the cables
asfo!lows.
• Apply a thin Coating of grease to the cable upper ends.
• Lubricate the cable by seeping the oil between the cable and cable
housing.

Parking Brake Cable Inspection

.With the cable disconnected at both ends, the cable should move
freely within the cable housilng.
*If the cable does not move freely after lubricating, or if the cablie is
frayed, or if the cable housing is kinked, replace the cable.
 SU.SPENSION 13·1

S:uspension
T'able of Contents

Exploded View ........................................................................."................................13-2

Struts and Rear Shock Absorbers ................................................................................13-3
Strut (Front Shock Absorber) Removal ..................................................................13-3
Strut (Front Shock Absor:ber) !Installation ................................................................13-3
Rear Shock Absorber iRemoval ..................................................................................13-3
;Rear Shock .Ahsorber Insta,Uation ...........................................................................13-3
Shock Absorber Inspection ........................................................................................13-3
Front Suspenslion Arms...................................................................................................13-4
Front Suspension Ann ·Removal ...................................................................................13-4
Front Suspension Arm Installation ...........................................................................13-4
Front Suspension Ar:m Inspection ............................................................................13-4
Leaf Springs and Dampers ................................................................................................13-5
Leaf Spring Removal ...............................................................................................13-5
Le·af Spring Installiation .............................................................................................13-5·
Le·af Spring Inspection ..............................................................................................13-5
13·2 SUSPEN"SION
Expl,oded View

n : 44 N-m (4.5 kg-m, 33 ft~)

1'2: 58 N-m (6.0 kg-m" 43 ft-lb)
T3 : 78 N-m (1.0 kg-m. 58 ft-Ib)
T4 : 98 N-m (10.0 kg-m, 72 ft-tb)

~;c\
ct)
 SUSPENSION 13-3
Struts and Rear Shock Absorbers

Strut {Front Shock Absorber) Removal

• Remove:
Front Fender Upper
Front Wheel
Strut Clamp Bolt and Nut [A]
Strut Mountin.g Nuts [8]
Strut (Front Shock .Absorber) IC]

Strut (Front Shock Absotber) Installation

.llnsert the strut to the steering knuclde [A] while aligning, the notch
on the strut with the clamp bolt hole on the steering knuckle.
• Torque:
TOI'qH- SInd MoIiInIInI NuIB: .. Nom (4.5.kg-m, 33ft.1b)
SInaI ClampNllt 98 N-m (10.0 kgoml,72 ft-Ib)

Rear Shock Absorber Removal

• Remove:
Rea.rWheel
• Hold the rear brake drum and panel assembly in position,
• Remove:
Leaf Spring Mounting Bolts and Nuts (loosen)
Rear Shock Absorber Mounting Bolts and Nuts[A]
Rear Shock Absorber [8]

Rear Shock Absorber InstaHation

• Install the ,rear wheel temporarily and ground it to load the suspension .
• Torque:
Torque - Rear Shock AbsGrber MOUldIng NulB:44 N-m (4.5 kg-rn, 33
ft...,)
Leaf SpringMounling Null (front): 98 N-rn (10.8 kg-m, 72 N)
Leaf Spring MOUI'IIIng Null (rear): 51 N-rn (6.0 kg-fn, 43 fI-Ib)

Shock Absorber Inspection

.Visually inspect. the shock absorber for breaks or distortion.
* If the shock absorber is damaged in any wa,y. replace it.
• Check for oil leakage at the shock absorber damper unit.
* If oil leakage is noted, Ihe shock absorber should be replaced to renew
the oil seal.
.Visually inspect the rubber bushings in the upper andlorlower
mountings of the rear shock. absorber.
*If they ar,e wom, cracked •. hardened, or otherwise damaged. replace
them with new ones.
13-4 SUS·PENSION
Front Suspension Arms

Front Suspension Ann Removal

• Remove:
Front Wheel
.Hold the front brake drum and panel assembly in pos.ition.
'.·Remove:
Front Suspens.ion Arm Pivot Bolts [A]
Front Suspension Arm Jo·int Nut [B]
Front Suspension Arm Joint from Steering Knuckle
o Install a suitable nut on the stud of the joint and tap the nut 11:0 free the
. joint from the steering kI'luckle.
• Remove:
Front SUSPension Arm [C]

Front Suspension Arm Installation

.Clean the tapered portion of the front suspen.sion am'l joint and the
tapered hole of the steering knuckle, or the tapers willi not fit snugly.
• Grease:
Front Suspension Ann Joint Boot Sealing Surface [A]
.When the front suspension ann pivot bolts are tightened. install the
ann joint to the steering knuckle to position the ann within its operat-
ing angle•
• Torque:
Torque - Froid SUspensIon .Ann Pivot Bola: 98N-m (10.0 Icg-m, 72 ft-Ib)
Front SwpensIon Ann Joint Nut 78 NomCS.O kg-m, 58 ft.Jb) Good o
o Bad

Front Suspension Arm Inspection

.Visually ,inspectthe'front suspension arm for breaks or distortion.
*.Check
If the front suspension ann is damaged. in any way, replace it
the rubber bushings in the pivots.
*RepJace any bushings that arewom. ~. hardened. or otherwise
damaged.
 SUSPE!NSION 13-5
Leaf Springs. and Dampers

Leaf Spring Removal

.,Remove:
Rear Wheel
• Ho,ld the. rear brake drum and panel assembly in position .
• Free the brake hose, pipe, and cable from the I,eaf spring.
o Immediateliy wipe up any brake fluid that spills.

Brake flUid ,quickly ruins painted surfaces; 811J spilled fluid should be
camplelely wiped up immediately•

• Remove:
Rear Shock Absorber [A]
Damper Bracket Mounting Nuts [B]
Damper and Bracket [C]
leaf Spring Mounting Bolts and Nuts [D]
Leaf Spring [E]

Leaf Spring Installation

.When installing the rubber bushings to thele8f spring, lubricate them
with a soap and water solution.

Do not IDe engine 011 or peIroIeum dlslll..... 10 lubrlcale . .

buatlings becauselhey wm deIartoraIe Ihe rubber•

• Torque:
Torque - Damper Bracket Mounting Null: 44 N-m (4.5 q.m, 33 ft-Ib)
Brake Pipe Nipple: 1. N-m (1.8 kg-rn,13.0 ft.Ib)
.lnstaU the rear wheel temporarily and ground it to load the suspension
during the mounting nut tightening .
• Torque:
Torque - Leaf Sprtng MoenIng Null (1ronI):98 N-m (1.0.0 .kg-m., 72 ft.1b)
Leaf Sprtng MOUldIng Nuts (rear): 59 N~ (6JI: q.m~ 43 ft.I:I)
RearShoc:k Absorber MOIBdIng Null: 44 N-In (4.5 kg-m,33
ft.Ib)
• Bleed the brake line.

Leaf Spring Inspection

.Visually inspect the leaf spring for breaks or distolrtion.
*11 the leaf spring is damaged ;in any wav~ replace it
• Check the rubber bushings in the mounts and the damper.
*Rejplace any bushings or damper that are wom. cracked.• hardened•. or
otherwise damaged.
 STEERING 14-1

Steer.ing
Table of Contents

Expl,oded View ...................................... "" .............'..................... "...............................14-2

Specif,ications .......... ;..........".........................................................."...........................'14·,3
Steering Wheel and Main Shaft Assembly ........................ ,., ..........................,............14·4
Steering Whee'l Position Adjustment .: ..........,.......................................................14·4
Steering Wheet· Free piSy Inspection ...................................................................14·4
Steering Wheel ~tering" ................ "........."..................................................."......14~4,
Steering Wheel and Main Shaft :lnstaUation ........................................................14-5
Steering Gear Assernbly ...... "............ ".. ".. "........................."...............".......".."............. 14-6
Steering G,ear Assembly Remloval .............................."....................."...................14-6
Steering Gear Assembly Insta1lation ....... ,................. ".."....................".................. 014·6
Steering Gear Preload Adjustrnent ..................."...............".....................,...............14-7
Tie·rod Length Adjustment .......... "."................ "" ............ "..".................... "..............14-7
Dust Boot Inspection ....................." "............................".................... ".......... "" ...... 01 4· 7
Stee'ring Knuckles ..".........................................................................................."....... ,,14-8
Steering Knuck,le Removal .........".......'....................................".'." ...."............ "..,......,14-8
Steering Knuckle Installati,on ............. ".............................."..................... ,,""...........14·8
· 14-2 STEERING
Exploded View

n : 20 N-rn (2.0 ....... 14.5 ft.Ib)

T2: 34 N-rn (3.5 kg-m, 25 ....'
11: 39 N-m (4.0 ....... 29 ...)
T4: 41 N-rn (5.0 ....... 31 ft.Ib)
15: 52 N-rn (5.3 q.m, • tI-Ib)

KAF820B

M·
.,W
 STEERING 14-3
Specifications

Item Standard Service Limit

Steering Wheel:
Steering wheel free play 0- 20mm - --
Steering Gear Assembly:
Tire-rod length 51.5mm - ,--
(distance between groove and k>cknut)
1,4-4 STEERI'NG
Steering Wheel and Maiin Shaft Assembly

Steering Wheel Position Adjustment

eloosenthe steering main shaft bracket mounting nuts [A] .
• Adjust the steel'ing wheel posiition .
• Tighten the main shaft bracket mounting nuts securely.

Steering Wheel Free Play Inspection

• Check. steering wheel free play [A].
o Set the front wheels straight ahead. Gently tum the steering wheel left
and right. The steeriing wheel free play is the amount ,of travel in the
steering wheel, before the front wheels begin to tum.

Bleerlngl WINIeI Free Play

S1andarcI: • - 20 mm
*11'f steering wheel free play is not conect, inspect the following.
Steering Wheel Mounting Nut
'Intermediate Shaft Clamp IBolts
Steering Gear Assembly Mounting Brac:ket Bolts
Steering Gear Assembl,y Mounting Rubber Dampers
Tie-rod End Nuts
Steering Gear Preload Adjustment
* If the above bolts and nuts are tightened firmly, dampers are in good
condition, and the preload is adjusted correctly, the steerig gear
assembly is damaged and should be replaced as a unit

Steering Wheel Centering

.Test ride the vehicle.
*1:1 the steering wheel is not straight when the vehicle is traveling in a
straight line, do the followings .
• Check the tie-rod length and adjust it if necessary.
• Remove the cap and loosen the steering wheel mounting nut [A] .
• Push the vehicle in a straight line with no one aboard., and stop it
without tlJming the steering wheel.
• Remount the steering wheel so that it is straight ahead.
Torque - Steering Wheel ,Mounting Nut: 52 N-m (5.3 kg!-lll,38 fl.lb)
 STEEIR:ING 14-5

Steering Wheel and Main Shaft Installation

• Grease:
Main Shaft .Bushillg [A] (Ins.ide Surface and Flanged End)
Dust Cover [8] Lips
.Connect the intermediate shaft [C] to the main shaft and the steering
gear pinion in any position. Mount the steering wheel on the main
shaft temporarily.
• Adjust
Steering Wheel Positon Adjustment
Steering Wheel Centering
.TorquE!=
Torque - Inlennedilate Shaft Clamp Bola [D]: 20 IN..,. (2.0 Ikg-m, 14.5
ft.Ib)
14-6 STEERING
Steering Gear Assembly

Steering Gear Assembly Removal

• Remove:.
Front Fender Upper
Steering Wheel and Main Shaft Assembly
Radiator
Front Wheels
Tie-rod End Nuts [AJ
Tie-rod Ends [B] from Steering Knuckles
Olnstall a suitable nut'on the stud ·of the tie-rod end joint and tap the
nut to free the joint from thesteerintg knuckle,

Do nalloosen 1he,IIIHod end, IocImUIIa [eI. or the Ioe-In oIlhe front

...... will be cIaIged.

Steering Gear Assembly Bracket Bolts [OJ

Steering Gear Assembly (El andBracke1s

Steering Gear Assembly Installation

.Adjust if necessary:
Steering Gear Preload Adjustment.
Tie-rod Length Adjustment
.Clean the tapered portion of the tie-rod end joint and the ta.pered hole
of the steering knuck.le, or the tapers will not fit snugly.
• Grease:
Tie-rod End Joint Boot Sealing Surfaces [AJ
.Turque:
Torque - Steering! Gear Assembly Bracket Bolls: 52 'N-m (5.3 kg-m,
, 0
38 ft-Ib) Good o I Bad
TIe-rod End H.... : 34 N-m (3.5 kg-m, 25 ft.llb)
.Checlc
Toe-in of Front Wheels
 STEERING 14·7

Steering Gear Preload Adjustment

• Loosen the locknut.
.Tighten the rack guide spring cap to 6.9 N-m (0.70 kg-m, 61 in:lb)
of torque.
• Back off the cap 60 - 70 •.
• Tighten the locknut while preventing the cap from turing.
Torque- Rack Guide Spring Cap Lodmut: 39 N-m (4.0~, 28 Il-II,
Pinion [Al
Rack [B]
Rack Guide [C]
Spring [DJ
Cap [E]
Locknut[F]

Tie-lad Length Adjustment

.Check the length [A] of the tie-rod distance between the rod groove
[8] and the locknut [CJ. This distance should be the specified value
for both the left and right tie-rods.

TJe.rodLqlh (distance between groove and Iocknld)

Standard:S1.S mm
*If it is not, adjust the tie-rod length .
• Loosen the locknut and turn the adjusting rod [0] to achieve the
specified vall'ue.
• Torque:
Torque -Tie-rod End Locknuts: 49 N-m (5.0 ~, 38 ft-Ib)

Dust Boot Inspection

.Visually inspect the dust boots at both the ends of the steering gear
assembly.
* If there is any signs of deterioration, cracks, or damage, replace the
steering gear assembly.
1,4-8 STEERING
Steering Knuckles
Steering Knuckle Removal
• Remove:
Front Wheel
Front Brake Drum
Fr,ont Brake Panel Assembly
Tie~rod End Nut [AJ
Front Suspension Arm Joint INut [8]
Tie-rod End [CJ and Front Suspension Arm Joint [0]
from Steering KnuCkle
o Install' a suitable nuts on the studs of the tie-'rod end joint and front
suspension arm joint, and tap the nuts tD fiee the joints from the
steering knuckle and front sUspension arm.

! Do DDliooAn Iha tIHcId endloc:louts [El, orlile Ioe-In oIlile fronI

wheels wiD be cfuInIed.

Strut Clamp Bolt and Nut [F]

Brake Hose Clamp [G]
Steeringl Knuckle [H]

Steering Knuckle Installation

.Clean the ta,pered portions of the front suspension arm j,olint and the
. tie-rod end joint and the tapered holes of the steering knuckle and the
front suspension arm, or the ta,pers will not fit snugily .
• Grease: .
Axle Bearing Glrea&e Seal U,ps
Front SUSfJel1sion Ann Joint .Boot Sealing Surfaces [AJ
.Torque:
Torque - SInd Clamp Nul: • N-m (1o.0kt-m. 72 ft.1b)
Frant iuepenslon ArmJolld Nut: 78 N-m (8.0k~, 58 ft-tb)
TIe-rod End Nut: 34 N-m (3.5 q.,m, .25 ft-lb) 0' Sad
• Check:
Toe-in of Front Wheels
 FRAME 15,·1

Frame
Table 01 Contents

Exploded View ........"" ....................... ".. "' ............... ".....................................................1, 5-2

Seat and Seat Belts ............... "...................................................................................15-6
Seat Removal." ...........,................................... ".................................................,......15-6
Seat Installation ............................................".... ".................. "................,...............15,-6
Seat B,elt Removal .. "....... "." ..................................................."............. ".................15-6
Seat Belt 'Installation .......................... "......... "........................................................15-6
Cargo Bed ............. "............................"" ......................'.................................. "............ 15-7
Cargo Bed Remo,val .... "'..............................,..... ".....................................................15-7
Cargo Bed Installation ........................................................................................"'.15-7
Flront and Rear Bars ." ............. ".......................... "............................... "................ "." ....15-8
Front Bar Remova,I ................... "....... ".....................................................................15-8
IFront Bar Installation "........"............... ".. ".......................................... ".................... 15-8,
'Rear 'Bar· Removal ...................... ".... ".. "....... ".......... "........ "........................"......... "... 15-8
Rear Bar Installation .... ".......... "" ...... "................ "....................................... "............ 15-8
Front Fender Assembly ............. "......... "................................ "" ........... "........... "........... '5-9
Front Cover Removal ...................................................................."........ "....... ""." ...15-9
Friont Cover Installation ................................ "........................"....................... "......15-9
,Fr,ont Fender Upper Removal ....................... "' ....................... "...............................15-9
Front Fender Upper Installati,on ... ".... "................... "........'............................."....... ..1 5-9'
Front Fender End Removal "...... "........................ ".......... ".....................'.........".....15-10
Front Fender Left and Rlight R,emoval .............,................................,..................,15-10
Front Fender Lower Hemoval ......................... ".................. "...................'..............1,5-10
Front Fender Lower Installation .........................................................................15-10
Radiator Side Cover Removal." ............... ".......... ".........................."..... ".......... "...15-10
Radiator Side Cover Installation ...............................................................................15-10
Radiator Bottom Covelr Removal ........... ".........."...................... "................ ". "......15-11
Radiator Bottom Cover Installation .....................................................................15-11
Radiator Side Cover Flap Removal ............ ".............................. "..............................15-11
Radiator Side Cover Flap Ilnsta.llation ..................................................... "..............15-11
Floor Center Panel RemovaL ................ ".. "........... "......................... "....................15-11
Rear End Sub-frame ......................................................................".................. ".....15-12
Rear End Sub-frame Removal ............... "..................................."' ........................15-12
Rear End Sub-frame Installation .............................................................................15-12
15-2 FRAME
Exploded View

AD : .AppIy adhesive agenL

G:Applyg.......

n :. 34 N-m (3.5 kg-m, 25 ft-lb)

12: 44 N-m(4.5 kg-m, 33ft-lbt
13.: 145 N-m (15.0 kg-m, 110 ft..Ib)
 FRAME 15-3

•
@---I

@i - -
~
••
15-4 F'RAME

,"

1 ~~F~620B~~
________ ~

""/ I~~t)t(
. C\J~ ~
 FRAME 15-5

KAF620A

I "
15·6 FRAME
Seat and Seat Belts

Seat Removal
• Remove:
Seat Bracket Nuts [A]
Seat Brackets
Seat [Bl
Seat Back Mounting Nuts [e]
Seat Back [0]

Seat Installation
.Grease [A]:
Seat Bracket Inside Surfaces·
• Be careful not to overtighten the seat bracket: nu1S. After tightening the .
nuts, the seat must be moved up and down smoothly.

Seat Belt Removal

• Remove:
Seat Belt Buckle (longer) [Al
Seat Belt Buckle {shorter) [B]
Seat Belt latches [C]

Seat Belt Installation

.Torque:
Torque - Seal Belt MoImIInQ BollI: 34 N-m (3.5 ........ 25 ....)

NOTE
o The seat belt buckles far the operator and the passent/flf are identical.
The operatols buckle is longer. the pa$SfIfIgtJIs one Is shorter.
o The seat belt latches III'e same.
Cargo ,Bed

Cargo Bed Removal

• Remov,e:
Tail/Brake Light Assemblies
Rea.r Fenders
oTo prevent damage to them, remove them before removing the cargo
bed.
Hooks (un'lock) [A]
Mounting Pins [B]
Cargo Bed [el

Cargo Bed Installation

• Grease:
Cargo Bed Mounting Pins
.Apply adhesive agent
Cargo Bed Rubber Dampers (Bouom). [A]
Tail Gate Pivot Rubber Dampers (Left and Right)
 15-8 FRAME
Front and Rear Ba'rs
Front Bar Removal
• RemoV,e:
Headlight Leads (disconnect)
Front Bar Mounting Bolts [A]
Front Bar [8]

Front Bar Installation

.Be sure that ~Ile rubber grommets [Alare in place and the headlight
leads [B] run through the front fender nOtciles Ie] .
• Torque:
Torque - FranI lBar "CUllIng 80IIII (Lower): 145 N-m (15.0 'kg-m, 110
fti.Ib)
Front Bar Mounling BollI tur.er):.44 Nom (4.5 ...., 33 ft.I»)

Rear Bar Removal

• Remove:
Air Duct Clamps (iloosen) (A]
Front Bar Mounting' Bo,1ts (Upper) [B]
Rear Bar Mounting BOlts (Lower) [C]
Rear Bar [0]

, Rear Bar InstaNation

.Torque:
Torque - Front . . M'oanIng Bolls (Upper): 44 Nom (4.5 ...... 33 . . .)
Rear Bar MounIIng'BoiIII and Null (Lower): 44 N-m (4.5 kg-m,
33tt-1b)
 FRAME 15·9
Front Fender Assembly

Front Cover Removal

• Remove:
Front Cover [A]

Front Cover Installation

.,Installl the left and right flaps [8] to the radiator sides.

Front Fender Upper Removal

• Remove:
Front Bar [A]
Front Cover [B] ,
'GiloVe: Compaftmem (C] .
Front Fender Upper [0]

Flont Fender Upper Installation

.Be suretl1atthe rubber dampers. [A] are in place•

• Engage the hook [A] on the glove compartment with the hook [8]
on the frame.
15-10 FRAME

Front Fender End Removal

• Remove:
Front Fender Ends [A]

Front Fender Left and Right Removal

• Remove:
Front Cover
Front Fender Left [A] and Right

Front Fender Lower Removal

• Remove:
Front Fend!!!' Upper
. Steering Main Shaft and Intemlediate Shaft
Brake Hoses
o Immediately wipe up any brake fluid that spills.

Brake tIuId quldd, Nine painted IUIfaceI; any &pIled fluid IhauIcI be
camplelalywlped up 1mmed1al8ly•

• Remove:
Front Fender Lower [A]

Front Fender Lower Installation

• Be sure that the dampers [8] are in place.
.TorqlJlr.
Tonp - Brake Hose Banfo 8oIiI:25 N-m (2.5 q.m, 11..0 ft..I))
• Bleed the brake line after installation.

Radiator Side Cover Removal

• Remove:
Radiator Side Covers [A]
OLift the front. wheels off the ground, and loosen the strut upper
mountirtg nuts if necessary.

RadiiTtar Side Cover Installation

•.Apply adhesive agent
Radiator Side Cover TrimS [8]·
 FRAME 15-11

Radiator Bottom Cover Removal

• Remove:
Front Fender Upper
Radiator Mounting Bolts
Radiator B,ottom Cover [A]

Radiator Bo,ttom Cover Installation

• Be sure that the rubber dampers [8] are in place.

Radiator Side Cover Flap Removal

• Remove:
Radiator Side Cover
Radiator Side Cover Flap [A]

Radiator Side Cover Flap Installation

.Insert the flap outside end [AJ between the . front fender left or right
and the frame pipe.

Floor Center Panel Removal

• Removie:
Seat Lower Cover [A]
Floor Center Panel [8]
15-12 FRAME
Rear End Sub-frame

Rear End Sub-frame Removal

.IRemove:
Engine
Transmission Case
Rear End Sub-frame Mounting Nuts [A]
Rear End Sub-frame [8],

Rear End Sub-frame InstaHation

.Torque:
Torque - Rear End SUIMram. MaunIIng ,Null: 44,.,.. (4.5 kg-m,33 ....,
 ELECTRICA,L SYSTEM 16-1

Elect,rical System
Table of Contents

Exp!loded View ........................................................16-2 Armature Inspection .........................................16-1 9

Specifications ,......................................~ ..................16-4 Pinion 'Gearlnspection .....,................................16-19
Parts Location .........................................................16-5 Starter Motor Relay Inspection '........................16-19
Precautions .........................................."...................16-6 Starter Circuit Relay Inspection .......................16-19
Battery ................................................................,.....16-7 Fuel Pump and Relay ...,.........................................16-20
Electrolyte Level Inspection ...............................1'6-7 Fuel Pump Operational Inspection ..................16·20
Electrolyte SpecifIC Gravity Inspection ..............1'6-7 Fuel Pump Rel'ay Internal Resistance ..............16·20
Initi,al Charging ....... "' ......................................."..16-7 Radiator Fan ........".. "......................."......................1'6·20
Ordinary Charging ."'.................".........................16-8 Radiator Fan Circuit Inspection .. ,.....................16-20
Charging Systen'I,................,......"...,.........................16-1 0 Radiator Fan Motor Inspection ... ,., ...,.. ,., .....,.......,..16-21
Alternator Rotor and Stator Removal ..............1"S-10 Lighting System .......................,.........,..................,..16-21
Alternator Rotor and Stator InstaUlation ...........16-10 Headlight Beam Adjustment...........................,..16·21
Charging SystemOperationallnspection ........16-11 Headlight Replacement ....................................16-21
Stator Coil R~istance ....................................,.,.16 -11 Tail/Brake light Replacement .................,...,.....16-21
Regulator/Rectifier Inspection .......................,..16-12 Switches ................ "........ "" .....................................16,-22
Ignition System ..."........,.:..................."...".........."..."1,6,·14 ,Brake light Switch Adjustment ........... ,., ...,...,.....16-22
Spark PIu:gRemoval/lnstallation .....,...............,.16·14 SWiitch Inspection ................................,.... ,........16-22
Igniter Inspecti,on .........."..................................16,·14 Radiator Fan Switch Inspection ......................16-22
Pickup Coil Inspection ........................ "' ....... "' ..16-15 Coolant Temperature Warning Light
l~gnition Coil Inspection ............. '.......................16-16 Switch Inspection ...........................................16-23
Spark Plug Cleaning/Inspection ......................11 '6·116, Fuses .........."..........................................................16-24
Spark Plug Gap Inspection ...................,...........116-16 'Fuse Inspection ............... "......".........................16-24
Electric Starter System ., ... ,., .....,......................,..,........16-17 Electrical Wiring ..........................................................16-24
Starter Motor Removal ..........................,., .. ,., .......16-17 Wiring ,Inspection ................................................16-24
Starter Motor Installation ...........,............,..........16-17 Wiring Diagram
Starter Motor Disassembly .........;.....................16-17 (Igniter with 4 p.in connector) .............................. 16-25
Starter Motor Assembly ........................ ,...........16-17 Wi!iring Diagram
Carbon Blrush and Yoke Inspection ......... ,........16-18 (.Igniter with 6 pin connector) ............................. 16-26
Commutator Cleaning/Inspection ..,.,........ ,., .......16-19
16-2 ELECTRICAL SYSTEM
Exploded View

AD : Apply adhasIve agent.

L : Apply non-parmanent locking agent.

n : U N-m (0.80 Ikg-m, 78 In-IbJ

1'2: 17 N-m (1..7 kg-m, 12.0 ft.Ib)
1'3: 120 Nom (12.0 kg-m. tn ft.Ib)

Optional
 ELECTRICAL SYSTEM 16-3

l /
@.
, I
KAF620B I '
16-4 ELECTRICAL SYS.TEM
Specifications

I
Item .Standard Service limit .
Battery:.
Electrolyte level Between upper and lower level lines - --
I
Specific gravity 1 .2.65 @20·C (68·F) - .- -
. Charging System: !

Regulator/rectifier output voltage BatterY voltage - 15 V - _.-

Alternator stator coil resistance 0 . 2 - 0.4 C - --
; Ignitio'n. System: I
Pickup coil winding resistance 90 -1300 - --
Ignition coiils:
Primary winding resistance 3.4- 4.6 a - -- I

Secondary winding resistance 10- 16 kC - --

Spark plugs:
Standard plug NGKBMR2A - --
Gap 0.6 - 0.7 mm - --
Electric Starter System.: . I I

I
Starter motor: I

Carbon brush length 10mm 5mm

!
Commutator diameter 28mm ! 27mm
Switches:
Brake light switch
Radiiator fan switch connections:
9Nafter 10 mm pedal travel
!
- --
Rising temperature
i From OFF to ON above 86 - 9O"C - - ,-
(187 - 194·F)
nlling temperature From ONi to OFF below 81 - 85"C - --
(178 - 1SS"F)
Coolant temperature warning light I
!
switch connections:
R:isingtemperature From OFIFto ON above 108 - 114·C -, --
(226 -237°F)
Falling temperature From ON to OFF below 1 01 - 1: 07"C :
-, --
(214 - 225°F)

SpecIal Tool - Hand Tesler. 57001-983

 ELECTRICAL SYSTEM 16-5
Parts,Location
Hom (KAF620B)[A]
A.adiator Fan Switch [B]
Radiator Fan [iC]
Ground Lead (Hom Button, KAF620B) [OJ

Hom Button (KAF6,20B) [A]

Igniti!on Switch [B]
Coolant Temperature Warning Light [C)
Light Switch (0]
Brake Light Switch [E]

Ground Lead (Frame) fA]

Regulator/Rectifier [B]
Batterv[C]
Parking iBrake Light Switch [0 1]

Igniter [E]
Fuel Pump Relay [F]

Fuses [A]
Starter Circuit Relay [B]

Neutral Switch (A]

Spark Plugs [BJ
Coola l1t Temperature Warning Light Switch (e]
l

Ignition Coils [D}

Pickup Coils [E]
Starter Motor/Relay [F]
Ground Lead (Engine) [G]
Altemi5tor (H]
OH Pressure Switch [I]
Fuel Pump [J]
16-6 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions. that are musts when.
servic.ing electrical systems. Leam and observe aU the rules below.
o Do not reverse the battery lead connections. This will bum out the
diodes in the electricalpal1s.
o Atways check battery condition before condemning other pan.s of an
electrical system. A fully. charged battery is a must for conducting
accurate electrical system tests.
OThe electrical parts should never be struck sharply, as with a hammer,
or al!IGWedto faU ona hald surface. Such a shock. to the parts can
damage them.
OTo prevent clamageto elecrtrical paltS, do not disconnect the battery
leads or any other electrical. connections when the ignition switch is
on, or whi!le the engine is running.
o Because oftha large amount of current, never keep the ignition switch
tumed to the start poSition when the starter motor will not tum over,
or the current may bum out the starter motor windings.
OTake care Ratto short the leeds that are directly connected to the
battery positive (+) taminal to the chassis ground.
o Troubles may involve one or in some cases all items. Never replace a
defectivepalt without determining what CAUSED thefa.ilure. If the
failure was' brought on by some other item or 'items, they too must be
repailad or replaced, or the replacement part will soon fail again.
o Make sure aI/ connectors in the. circuit are eI!ean and tight. and examine
. wires for signs of burning, fraying, etc. Poor wires and bad
connections.wilil affect eJectrical system operation.
o M~re coil and winding resistanc:& when the part is cold (at room
anperature).
OColor Codes:
BK Black . LG Light Green
BL Blue o Orange
BR Brown P Pi!nk
CH Chocolate PU Purple
DG Dark. Green R Red
G Green W White
GY Gray Y Yellow
LB light Blue
o Electrical Connectors:
Female Connectors [A]
Male Connectors [B1
 ELECTRICAL SYSTEM 16-7
Battery

Electrolyte Level Inspection

,.The electrolyte level should be between the upper and lower level lines
[AJ.
* If the level of electrolyte in any cell is below the lower level line, add
only distilled water to the cell, until the level is at the upper level line.

Ordinary lap waler Is not a subatIluta for dlaltlled water alMl will .
shorIen Ibe life ollie baIlery. I

Electrolyte SpecirlC Gravity Inspection

• Check battery condition by testing the specific gravity of the electrolyte
in each cell with a hydrometer.
o Read the level of the electrolyte [A] on the floating scalile.
*If the specifi.c gravity is below 1.20 (charge 60%). the battery needs
to be charged.
NOTE
o The specHic gravity of the electrolyte v8Iies with changes in
temperature. so the specific gravity r.eading must be coaected for the
tempera.ture of the electrolyte.
o Celsius: Add 0.007 points to reading for each 1·(J'C above 20' or
subtract 0.007 points for each 1(fC below 2(fC;
o Fahrenheit: Add 0.004 points to reading for.each 1UF above 68'F
or subtract 0.004 points for each .10'F below BB"F.

Initial Charging
• Remove the battery.
nWARNING

Keep 1he batI8ry away from sparks and open ftamee during charging.
since Ibe baaery gives off an expIoalH gas mlxlln 01 hydrogen and
oxygen. When ..1ng a balllery charger, connecIlhe baIIery 10 the
charger before lundng on Ibe charger. This procedure prevents
sparks at Ihe batIery terminals which coulcllgnle .any baIIery ......

• Fill ,each cell to the upper level line on the battery case with fresh
electrolyte (specific gravity: 1.265) at a temperature of 30°C (86°F) or
less. Let the battery stand for about 30 millnliltes before charging.
NOTE
o If the electrolyte level drops, add electrolrt.s, to the upper level line
before charging.
• Set the charging. rate a 1/10 the battery capac.ity. and charge it for
10 hours. For example, if the battery is rated at 14 Ah. the charging
rate would 'be 1.4 A.
16-8 ELECTRICAL SYSTEM

bale"
I lite Is not given a lull Initial charging, II will dlsctlarge In a '
few weeks. After Ihat It can not be charged by supplemenlal
charging.
AIw.,. remove lite baUery t1rom thevehlclle for charging. II the '
,i battery Is charged while • I....I~. ballery eleclrolyte may spill
and; corrode the trame or allier parIB ,ce the vehk:Ie.
Do noI '... a high ..... ballery charger, as IslyplcaU, employed at
autamollve 88I'V1ce SIatIon8. unleu 1M charger nile can be reduced
. liD the .1eve1 .....1red. Cbarglng the baIIery at • nde higher than
specIIIed may ruin the baDery. ChargIng at • high raIa 'C8U888
'uceaa heat whlich can warp the plates and cawe lnIemal shorting.
HIgher......nonnaI charging raIIes aIIo _ _ the pIaIe8 to ailed
active malerial. DepoIIIs will, 8CCUIIIUIate, and can _ Inlamal
shorting.
IIIIe tamperalUre of lite eIecIroIyIe rises above .soC (115"F) during
charging, reduce the chargtngi nile to lower ... 18mpera1Ure. and
Incre.e chargtng lime proportIOnat81y.

Ordinary Charging
eRemovethe battery.

i .. \NARNING
Keep the baaery away t1rom spm1Cs and open flam. . during charging,
since the baII8Iy glvel 01 . . axpIoBIVe gas mldure of hydrogen and
oxygen. WI'I8n uaIng a baIIary charger, comecI the balery liD . .
charger beforellumtrlg on the charger. lbls prGC8dIn pnwenII
sparks at the ba:8ery lemlinals wfdctI· could ignite any baIIery gB888.

.Set the charging rate and time according to the battery condition
previously determined (see Electrolyte Specific Gravity Inspection),
using the Battery Charging Rate/Time Table.
• Check the electrolyte level a:ftercharging.

AIwaya remove the baIary from the vehicle for chargilng. I ilia
baIIary Is chIIrged whlle ...1 InIitaUedl,. biliary efecIrotlle mayspll
and corrode lite frame or oIher paris of Ihe vehicle.
Do DOl use 8 hlgb ..... iballery charger, • Is typically ~plDyeclat
auIaInGtIve senlce BIaIIoaa, ...188B ... cbarger rata can be reduced
lID. the level required. Charging'" lballery at ...... higher Ihan
lpecIIed may ..... the batIery. Charging at a high raIa C8UI88
UC8IS beat which can warp . . plalesand cause 1nIama1: 1hortIng•.
HlIPtr-IhaJli"iIOI"mat clwglng ...... also cause the pIaI88 liD ailed
actJvemalartat. Depoell:s wlar accumulale, and can cause InIamaI
shorting.
1 the ......
III'IlIIper
__ ....... of the ~,.. rIa88 above 45"C (115~ during
• ~ reducelhe.cihargIng ..... to 'Iowerlhe lampelalure, and
IncrI88e charging _ proportIOnat8ly.
 ELECTRICAL SYSTEM 16-9

Balttery Charging Rate./Time Table (12 V 19 Ah)

1.265 -+-;:::::::"'__....;...~..=.:.;,;:.:...:..:..:....;.
1.24
1.20'
U6 Sample
1.12
1'.08
1.04_._00
1 - - -_ _1.00
at 1A charge rate
jlJl••
at 2A dlarge rate
at 3A charge rate

---.II.... Hours of Charging Time at Rates Shown

16-10 ELECTRICAL SYSTEM
Charging System

Alternator Rotor and Stator Removal

e Remove, if the engine is mounted on the frame:
Carg'o Bed
Propeller Shafts
eRemove:
Altemator Cover [A]
Starter Motor [8]
Pickup Coils [C]
Altemator Rotor Nut [0]
o Hold the alternator rotor with a holder.
Alternator Rotor IE]
o Ipull the alternator rotor with a puller.

NOTE
Olfa puller is not available, screw the alterna.tor roto; nut [A] flush
with the shaft end to prevent damaged shaft end threads and tap
sharply and squarely on the nut to break the rotor loose.

CAUTION
, Do ROt atlampt to BIrIat the alamalDr JIIOIor...... SIrIdng Ihe roIDr !

can ClUMIhe magneIs tID lose ItIeIr megneIIsm"

-Remov,e:
Alternator Stator Mounting Screws [A]
Alternator Stator (8]

Altemator Rotor and Stator Installation

eApply non-pennanent locking agent
Altemator Stator Mounting Screws
.Clean the ilnside o,f the alternator and end of the crankshaft or the taper
wil!1 not fit snuglr,-..
e Fit the rotor onto the crankshaft so that the key fits in the groove in the
hub of the rotor.
• Torque:
Torque - MemaIIor Ralor Nut : 120 rHn (110 Ikg-m, t!f1 .-Ib)
e Route the etectrical wiires.
 E.LECTRICAL SYSTEM 16-1:1

Charging System Operations/Inspection

.Check. battery condition.
NOTE
OAlways check battery condition before condemning other parts of
the charging system. The battlNy must be fully chatged in order to
co[lduct accurate charging sysmm tests. .
.Warm. up the engine to bring the components up to their normal
operating temperatures.
• Measure regulator/rectifiero!IJtput voltage at various engine speeds
with the headlights turned on and then turned off .
o Connect a voltmeter across the battery terminals.
*The readings should show nearly batteIy. voltage when the engine
speed is low, and as the engine speed rises,. the readings should also
rise. But they must stay within the specified range.
*If the output voltage is much hig.her than the specification, the
regularor/l'eCtifier is defective, o,r the regulator/rectifier leads are loose
or open.
*If the output voltage does not rise as the engline speed increase then
the lregulator/rectifier is defective or the altemator output is insufficient
for the loads.
RegulatorlRecIIIIer 0uIIMd Vollage
Standard: BaII8ry Vollaga ... 15V

Stator Coil Resistance

• Disconnect the alternator lead connector.
• Measure the stator coil resistance.
o Connect an ohmmeter between the alternator leads.
Slab' CoIIIReslstance
Standard: 0.2 ... OA 0
*11.f the meter does not read as specified, replace tAe alterna.tor stator.
*If the coil has normal resistance, but the voltage inspect showed the
alternator to be defective; then the rotor magnets have probably
weakened, and the rotor must be replaced.
16-12 ELECTRICAL SYSTEM

Regulator/Rectifier Inspection
Rectifier Circuit Test:
• Remove the regula,tor/rectifier [A) .
• Check the resistance in both directions between the terminals follow-
ing the table.
*The resistance should be low in one direction and more than ten times
as mudh in the other direction. If any two tenni,lnals a.re low or high in
both directions, ~ rectifl8r is defective and must be replaced.
N,OTE
a The actual meter reading varies with the meter used and the
individual rectifier, but. genetally speaking the lower reading should
be from zero to the first % of the scale.
RecIIIIer Cln:ullnlpectlDft
COnnections Meter
No. Meter (+) to Meter (-) to Reading Range
1 A1 B '00 x 10 n or
2 A2 x100n

3 A1 G 0-%
,

4 A2 scale A1 A2
,
5 B A1!
6 A2
7 G A1 00

8 A2 , !
,

Regulator Circuit Test:

• Prepare testing tools:
Test Light Bulb ~ 12 V aod3 - 6 W
Batteries 12 V 'battery and 6 V battery
Test Wires 5 auxiliary wires

The lest light Ilmls the currenI flow through the .reguIaIor/recdler.,
• Do not ... an ammeter ormulllmet8rln lIB place.

Regulator Circuit Test-1 st Step:

.COnnect the test light and the 12 V battery to the regulator/rectifier as
shown.
• Check A1 and A2 tenninals respectively.

. The lest IIgM lImBs. the current flow through the regul8lorJrecllfter.
Do IIGII_ .... IUII _ _ or mulllm..... In . . pa-.

*Ifthe testlighttums on, the .regulator/rectifier is defective. Replace it

*If the test light does not tum on, cootinue the test.
 ELE.CTRICAL SYSTEM 16-13

Regulator Circuit Test-2nd Step:

• Connect the test light and the 12 V battery in the manner specified in
the "Regulator Circuit Test-1 st Step."
.Apply 12 V to M terminal.
• Check A1 and A2 terminals respectively.
*If the test light tums on, the ,regulator/rectifier is defective. Repl!ace it
*It the test light does not tum on, continue the test.

Regulator Circuit Test-3m Step:

.Connect the test light and the 12 V battery in the same manner as
specified in the "'Regulator Circuit Test-1 st Step."
• Momentarily apply 18 V to M terminal by adding a 6 V battery.
• Check A1 and A2 terminals respectively.

CAUTION
Donal apply more than 18 V to Ihe ragulalOr/recllller and do nalleave
• the 18 V applied lor more I1an a lew seconds, or Ihe unit will be
damaged.

*I.t the test light did not light when the 18 V was applied momentarily
to the voltage monitoring terminal, the regulator/rectifier is defective.
IRep!lace it.
*If the regulator/rectifier passes all of the tests described, it may still be
defective. If the charging system still does not work properly after
checking all of the components and the battery, test the
regulator/rectifier by replacing. it with almown· good unit.
16-14 ELECTRICAL SYSTEM
Ignition System

.... WARNING
, The Ignllon system produces extremely high voltage. Do not lauch
the spark plug" hlghlenslon,coll, or spark plug lead while the eng.ne I

Is rIIInnlng, or you could receive a severe eledrtcal shock.

Spark Plug Removal/lnstallation

• Remove the spark plugs with a Hex: 19 long type socket wrench.
• Torque:
TorcpI8 - Spart ptugs: 17 N-m (1.7 kgom,12.0 fI.Ii»)

Igniter Inspection
• Measure the igniter internal resistance shown in the table.
SpecIal TooI- HIInd T8IIer: 57001-183
*If the meter readings are not as specified., replace the igniter.

Use 0IIIIr KawasakI handl tasIar for ilia test. A IHI:er oIher Ihan . .
Kawasalc:1 hand tasIer may show dlllarent read.....
I a megger or a metar with a Iarge-capacIIy ballerJ Is used" . .
igniter will be damaged.

igniter Inlemal Reslslance (4P + 4P Connectors, PIN. 21119-2120), (x1kO)

Tester(-) Lead Tester ( +) Lead Connection

ConnecIIon I
W BKIY BKIW Y GtW P W/BL OIW

- I
W 00 1 - 8 , 4 -16 I 2-8 4 -16 2 -8 2 -10

I
BKIY 00 - 1 - 8 4 -16 I
,
2-8 4 -16 2-8 2 -10
, BKIW 00 00 - 1- 6 0 1 - 6 0 0.5 - 2
Y 00 00 1, - 6 - 0 3 -12 1 - 6 2-8
G/W 00 00 0 1- 6 - 1 .... 6
I

I 0 0.5 - 2
,
p 00 00 1 - 6 3 -15 0.5 - 2 - I
I 1 - 6 1 - '6
W/BL 00 00 0 1 .... 6 2-8 1 .... 6 - 0.5 .... 2
,
I

il OIW 00 00 0.5 - 2 2-8 0.5 - 2 2-8 0.5 -2 -

 6P + 4P Connect.ol'S

igniter 'Internal Resislance (IP + 4P ConneCIDnI, PIN. 21119-1451) (x 1kO)

Tesler (-) iLead T.... (+) Lead Col. . . .
I
ConnectIon A B C 0 E F G H Ii
A - ao I
, 1-8 2-9 3-16 , -8 3-16 1-8 2-8
B 00 - 1-8 2-9 3-16 11 ... 8 3-16 1-8
,
2-8
I
! C ao ao - 0.1-2 1-6 0 I 1-6 0 0.1 -1
,

-
I,
0 ao , ao O.1f-2 2-8 0.1 -2 2-8 0.1-2 1-3
E ao ao 1-6 2-8 - 1-6 3-12 1-6 ! 1-6
,
F 00 ao i
0 0.1-2 1-6 - 1-6 0 I 0.1-1
G aci ao 1-6 2-8 3-12 1-6; - 1-6 1-6
H ao ao 0 0.1-2 1-6 0 1-6 - I 0.1-1
I ao ao 0.1-1 0.1-3 1-7 T 0.1-1 1-7 0.1-1 I -

Pickup Coil Inspection

• Measure the pickup coil resistance.
Pickup Coil Reslslance
Standard: 90- 130 Q
*If fhe resistance is not as specified. lreplace the plickup coH assembly.
16-16 ELECTRICAL SYSTEM

Ignition Coil Inspection

e Measure the ignition coil resistance.
Measure primary winding resistance [A].
Measure secondary winding resistance [8].
Ignlllon CoIl WInding ....1IIIInce
PrfmaIy Windings: 3A .... .u 0
Secondarr WIndIngI: 10 .... 1111:0
*If the does not read as specified, replace the coil.
meter
*Ifgood.
the meter reads as specified, the ignition coil windings are probably
However, if the ignition system still does not perfonn as it
should after all other componen.ts have been checked, test replace the
coil with one knOwn to be good.
eCheck the spark plug lead for visible damage.
*If the spark plug lead is damaged, replace the coil.

Spark Plug Cleaning/lnspection

-eCiean the. spark plug, preferably in a sandblasting daw:e, and then
clean off any abrasive partictes. The plug may also be cleaned using
a high flash-point solvent and a wire brush or other suitable tool.
*'t the spark plug electrodes are corroded or damaged, or if the insulator
is cracked, replace the plug. Use the standard spark plug or its
equivalent
Insulator .[Al Plug Gap [C]
Center Electrode -[8] Side Electrode [0]

Spark Plug Gap Inspection

'. Measure the gap with a wire-type thickness gauge.
*It the gap is incorrect, carefully bend the side electrode with a suitable
tool to obtain the correct gap.
Sp8Ik Plug Gap
SIandanI: 0.& -0.7 mm
 ELECTRICAL SYSTEM 18-17
iElectric Starter System

StaTter Motor Removal

.,Remove:
Torque Converter
Starter Motor leads (from Starter Motor) [A]
Starter Motor Mounting B·Oilts (8]
Starter Motor [C]

Starter Motor Installation

.Clean the starter motor legs [A] and the crankcase where the start.
motor is grounded [B].

Starter Motor Disassembly

.Cover the starter motor with a clean cloth to keep the carbon brush
springs from flying off while rernOYing the end cover [A] and the brush
holding plate.

Statter Motor Assembly

• Inspect the dust seal [A], grommet. {B], plug [C],. and boot [0] fo,
visible damage.
*If they are damaged, replaoe the damaged parts.
16-18 ELECTRICAL SYSTEM

• Fit the notch [A] in the ( -) 'lead grommet onto the projection [8] on
. the yoke.

• Grease the pinion gear fork fingers..

• Set the pinion gear fork so that the fingers fit into the groove j,n the
gea,r.
• Fit the notch [Al in the yoke onto the projlecdon [8] on the pinion
gear fait.

• Engage the hook. [Alan the starter motor rel8¥ with the hook [8] on
the pinion gear fork.

Carbon Brush and Yoke Inspection

• Measure the carbon brush-length [A].
*11 the brush length is less than the serv,ice limit, replace thevoke
assembly.
Carbon Brush LengIh
Standard: 10 mm
Service Limit 5 mm

• Measure the resistance between each (-) side carbon brush [AJ and
the yok.e body.
* If there is not close to 0 0, the field coils have an open and the yoke
must be repl;aced .
• Measure the resistance between the (+) side carbon brush [8J and
the yoke body.
* If there is any meter ireading, the ( +) side carbon brush has a short and
the 'tOke must be replaced.
 ELECTRICAL SYSTEM 16-19

Commutator Cleaning/Inspection
• Smooth the commutator SlJlrface [A] if necessary with fine emery cloth,
and clean out the grooves as illustrated.
• Measure the diameter of the commutator.
*Replace the starter motor with a new one if the commutator diameter
is less titlan the service limit.
CommuIatorDiameler
Standard: 28 nun
SerVIce limit 'Z1 nun

Armat~e Inspection
• Measure the resistance between each segment [A] and all the others.
* If the resistance is too high or even infinite, the annature winding has
an open circuit.
• Measure the r,esistance between the commutator a,nd the a,rma,tul'l'8
shaft [B].'
* If the resistanoe is less than infinite, the armature is sho'rtedl..

Pinion Gear Inspeciion

.Turn the pinion gear -[AI by hand. It should tum counterclockwise
freely [B], but should not tum freely clockwise [C]. It should tum
, with the shaft [0] clockwise.
*If the p,inion gear does not operate as it should or if there is any wom
or damaged part,. replace it

Starter Motor Relay Inspection

.Connect an ohmmeter and 12 V battery to the starter motor relay [A]
as shown.
* If the relay does not work as specified, the relay is defective.
Testing Relay
Meter Range: x1 (} lrange
CrIterIa: When baII8ry 18 connected .... 0a
When baIIery Is dIaconnecIed .... IX)

Starter Circuit Relay Inspection

.Connect an ohmmeter and 12 V battery to the starter circuit relay [A]
as shown.
*If the relay does not work as specified, the relay is defectiv,e.
Testing Relay
Meter~: x1ar~
CrIteria: When batIery Is connectec:l .... 0 a
When baII8ry Is disconnected ... 00
16-20 ELECTR.ICAL SYSTEM
Fuel Pump and Relay

The fuel pump does not operate when the ignition switch is tumed
on alone. The 'pump operates when the engine is running.
When fuel level in the float chamber is low, the fuel pump operates
to supply fuel into the float chamber.
When the fuel .reaches a certain level., the fuel pr,essure rises, and stops
the fuel pump.

Fuel Pump Operationa/lnspection

• Remove the fuel pump [Al and the fuel filter [8].
.Prepare a container filled with kerosene [q .
• Prepare the hoses, and connect them to the pump fittings .
• Connect the 12 V battery to the fuel pump leads.
Fuel: Pump Leads .
SKIlL.... BaIIary (+)
SKIY . ....BatIIIr)' (-)

*If the pump does not operate, .the pump is defective.

• Close the outlet. hose while. opet:ating. the fuel pump.
* If the pump does not stop, the pump is defective.

Fuel Pump Relay Internal Resistance'

.Measure the fuel pump relay internal resistance shown i." the table.
*If the measurements are not ,as· specified, replace the relay.
FuM Pump Aelaylnl8mal Resistance (x1 IkO)

Tester(-) Lead I Teater (+) ..... Cor..'18CIIon

ComecIIon SKIW BL SKlBL

BKIW . - ao ao
SL
,
00 - ao
I

SKIlL ao More than -

10kO

Radiator Fan

Radiator ,Fan Circuit Inspection

• Disconnect ~he leads from the radiator fan switch .
• Using an auxiliary wire [A),connect the radiator fan switch leads
[8].
*If the radiator fan rotates, inspect the radia,torfanswitch.
*If the radiator fan does not rotate, .iinspect the following.
leads and Connectors
:RadiatorFan Fuse
Radiator Fan Motor
 ELECTRICAL SYSTEM 16-211

Radiator nan Motor Inspection

• Disconnect the fan motor leads [A] from thefan .
• Using two auxiliary wires, supply battery power to the fan motor.
*If the fan does not rotate at this time, the fain motor is defective and
must be replaced.
Radiator Fan Motor Leads
BL -+ 8aIIeI'y ( + )
BK -+ BaItery (-)

Headlight Beam Adjustment

.loosen the headlight mounting nuts [AJ and tilt the headlight to,
adjust the headlight beam .
• ,Tighten the mounting nuts.

Headlight Replacement
• Replace the he8dlight as an assembly.
o Remove the mounting nut [A.] .
• Adjust the headlight beam after installation.

Tail/Srake Light Replacement

• Remove the lock pin type bulb [Al.
o Remove the tail/brake light lens.
o Push the bulb in, tum it counterclockwise, and pull it out ,of the socket.:

I Dota _ _ _ *"':::"_... __ _
o Be careful not to overtighten the lens mounting screws.
16-22 ELECTRICAL SYSTEM
Switches

Brake Light Switch Adjustment

eCheck the operation of the brake light switch by depressing the brake
pedal. The brake light should go on after 10 mm of pedal travel [A].
*If it does not. adjust the brake light switch [8] up or down. To change
the switch position •. tum the adjusting nut [C].

I~--"-=--"--I
8Ufit Ihat ... swIII:II bodr doa8 nat un during adjustment.

Switch Inspection
.Using an ohmmeter, check to see that only the connections shown in
1'Ihe table (see Wiring Diagram) 'have continuity (about zeroo'hms).
*If the switch has an open or short. repair it o,r replace it with new ,one.

Radiator .Fan Switch /,.ection

.Suspend the switch [AJin a conUliner of coolant so that the temper-
ature sensing, projection and threaded portion are submerged.
eSuspend an accurate thermometer [8] in the coolant.

NOTE
o The switch and thermometer must not touch the container sides 01
bottom. A
• Place the conUliner over a source of heat and gradually raise the
temperature of the coolant while stirring the coolant gently.
e Using an ohmmeter, measure the internal resistance of the switch
across 1'Ihetemlinals a.t the temperatures shown in the table.
*If the meter does not shoW the .specified values. replace the switch.

iRadlalor Fan SWtIch ReaIsI:ance

o RIB_ tamperaIUre:
From OFF 10 ON at 86 - 9O"e (187 - 194"f)
OFallng·~
From ON 10 OFF at 81 - we (178 - 185"F)
ON,: ..... than 0.50
OFF: More than 1UO
 ELECTRICAL SYSTEM16~23

Coo~ntTenpeature~arnmgL~htSwgchJnspecUon
.Suspend the switch [AJ in a container of coolant so that the temper-
ature sensing projection and threaded portion are submerged .
• Suspend an accurate thermomet.er [8] in the coolant.

NOTE
A
o The switch and thermometer must not touch the co'ntBiner sides or
bottom.
• Place the container over a source of heat and gradually raise the
temperature of the coolant while stirring the coolant gently.
• Using an ohmmeter, measure the intefnall resistance of the switch
across the connector and the body at the temperatures shown in the
table.
*If the meter does not show the speciffed V8,lues. replace th,eswitch.

Coolant Ternperalure Warning ILItiM SWIIdI ResiIII8nce

o Rising tamperalure:
From, OFF 10 ON 811:08 -1'IIC"C (228 - 237"F)
OFallng temperature:
From ON 10 OFF 81101' -1OTC (21:4 .... 225"F)
ON: LeIs tIUIn 0.5a
OFF: More than 1 MO
16-24 ELECTRICALSVSTEM
Fuses
Fuse Inspection
• Inspect the fuse element (AJ.
*,fit is blown out, rep.lace the fuse. Before replacing a blown fuse
[B], always check the amperage in the affected circuit. If the
amperage is equal to' or greater than the fuse rating, check. the wiring
and related components for a short circuit

When repIIlclng a fu8e, be sure lite . . . Me mak:I_ Ihe specIIecI

fu8e rating far IhaI circuli. lnelallationof a ....... a higher I'IdIng
may cause damage 10 wiring and componIIIiII.

NOTE
o The fuse cases must.be installed with the clamp side [CJ down.

Electrical Wiring

Wiring Inspection
.Visually inspect the wiring for signs of burn.ing, fraying, etc.
"*• Pull
If any wiring is poor, replace the damaged wiring .
each connector ap.art and inspect it folr corrosion, dirt, and
damag,e.
*If the connector is corroded or dirty,clean 'itca.refully. If it is damaged,
replace it
• Check the wiring ~or oontinuity.
o Use the wiring diagram to find the ends of the lead which is suspected
of being a problem.
o Measure the resistance between the ends of the leads.
* If the resistance is not 0' 0, the lead is defective. Replace the lead or .
.the wiring loom if necessary.
 <D m.I,,:!=======+.
:g(i:"I:j::::======l,
Fue'
CrRv -
--II ~
cJ) IIt>tlonll parte (for EXlNOII)
"' ......... ---..... _------_ .. -_ .. ---_ .......... ----
cJ)
®
:~.I',:t======t:t:U
~UI :I:=======:f:tiJ Iii l
tP'U nu
JJ.1r,L
illrtTf
e
IOU
IV I
IInlltr RIIUI,I°r!
Rtot II
i I: ::::;rp '''OIf
I 3. Hour Miler
: •• Vlllir

~; ~l,'mJ ~
: f. (m:r:~t~~~U(in ""o\fftUrf
<I>
t Ott ' " ••"n Vlrnlnl

mf4~~rF:~!====~ttt
: Plrllnl Inte
I COO lint U8PlritUri Warning
I •. Roor WarnlnO L1lht
: t. CillO Bid L loht

I§§JW1lt/o---~ i :: ::~~ Button

: 10. Allern,tor
l!~: !~~! ______ . _____ ........ __ . ____ . ___ _
5gn'R~ m~tlllur'(jC/~/Io===:tiHttt1

Lloht Swllch

Till/Brite
LlohU
12V6/21WX2

L-L8~ Neulrll SwllCh

@j:.lh~I"======~
KUUOA
@j:.1,,::&,I'rr======-W
[. ·~~~-_~r,-t'h
[ lilt!:. ~'"'~~,============::'
m
r-

t.
m
<I> ~'I~I==============~ Color cooe ~
-------------------
uruo.
~:m~or Fan II,

-
:xJ
o
»r-

rl1l!lnT~
'I~
L--Il/ r
Horn
----------------.--
0
.onltlon IYltoh Conn,oUonl

IK/r '11K IK/I II

orr c. iooo
,
LI,ht 'vUoh
Connl'" onl
I OFF I I I
IInIIIlU" ce...... N.
(1"''''''
I I II
In •• Ll,ht l"Uoh

I -I TII.lntll Ter.lnIIIIF='I":"'I:-:JW::'1I1r:'~I/;:"1111
conneoUonl

I II I IL I
I I I
Plrllnt Inll Lilftl IVllOb cun.ollOn,

I"..,..!f......ll
I I II
.'.Inl Switch Connactlonl

I I""ln'll Bround I
I I I
• • w
~
~
m
~

ON c. 01() I ON I I ,ulb on I ()oIIj.o Ilwbl. 'rail "~'I 10 ,ulbl~ ~own I ()oIIj.o I ........... "", "m " "11"" ••r -~ 1 r.l.ml II) '01l1l,nl c::-+--:> I
srAn (,uee. '1211)'
 ootlon .. 'arts (tor EIUDII)
------------
,.--t .•lot-uP all.,er ---
------ ------- -----
- ~
~
:::!,
CC
~
0)
I
N
0)

2. SOC'lt
3. Hour "Iter C m
4. VI,., ;' r-
6.lndlcltor LlGhts( In SDeedO,.lter)
CC m
Ql n
I II lllil n.1 Ion
011 pna.url WarninG
'o,llno a.. le -t
--
eOOllnt TIfIPlultura warninG
8.RoOI va,nlno LIOn!
'.ClrGo a.d LIGht
3 :D
I. Horn autton
I. Horn
10. AI ternltor
;S l> n
! _1_1~ !.U!-,_:. ________________________ ._ ~
r-
i'
., 0 -<
LI ohl Swllch ,...~,
-t
0
=r m
0) s:
TIll/a .... '1J
LlOhll
12Y6/21VX2
:i'
8
~
~

.,~
IAIUOA
-
r·-------··a;-~f:~::t:iif]2l:oltT,=========.J
I
I
L .• _._J ] - -
r--- --.. -.- -.. -- -- ---
II IL__._ ..___________
©trm
Im:h LlOhl If =============::::J
--\<HI/T'--------#H
II (I) rif_IK-.--===========~
lli.-e~~a ,1- colo, code
L__________________ ~. .J
::?u~or Fan
IAIU08
~~f_t=,======~
1---'-'-------------------------,
I ,

f;;~~I======::='J1
,: 11/1-(>.
i
I .
I L_., lonition swltoh Connlotlona Llont swltoh 1".1 LIOht Swltoh conneotlonl PIIllno .'11, LI.II switch COnn.cllon. ..Ullli Swilch connocllon.
. II/T-::Ci Connlot lona

l________:D_:.___ JrQ! orr

§O~Mt=tj~~~~t1 L..:"-'_~-'-_=-...J L.:="':'::'L...::..:...L=~ L -____________
Vh.n '"I' ,ldll .. ,.,h" aown ~~~
, .... 'IUlfi. ,,,I •• "., •• '111., It
 APPENDIX 17-1

Appendix
Table of Contents

. Troubleshooting Guide .............................................................................................17-2

General Lubrication ..........................................;........................................................17 -6
Lubrication ........................................................................................................17-6
Nut. Bolt;. and Fastener Tightness ............................................................................17-7·
Tightness Inspection ....................... ·.. ·.......... ·..................................................17-7
Unit Conversion Table ..............................................................................................17-8
17-2 APPENDIX
Troubleshooting Guide
NOTE Valve spring broken or weak
Valve not seating properly (valve bent wom,or
o This is not an exhaustive list giving every possible ·
carbon accumu Iatlon on the seating surface)
cause for each problem listed. It is meantsimp/y as a
rough guide to assist the troubleshooting for some of
the more common difficulties.
Poor Running at Low Speed:
spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Engine Doesn't Start. Starting Difficulty: Spark plug cap shorted or not in good contact
$tarter mptor not rotating:
Spark plug incorrect
Neutral switch trouble
Igniter trouble
Starter motor trouble
Ignition coil trouble
Battery voltage low
Pickup coil trouble
Relays not contacting or operating
Fuel/air mixture incorrect:
Wiring open or shorted
Pilot screw maladjusted
Ignition switch trouble
Pilot jet or air passage clogged
Fuse blown
Air bleed pipe bleed holes clogged
Starter motor rotating but engine doesn't
Air cleaner clogged, poorly sealed, or missing
turn over: Choke valve stuck closed
Starter motor trouble
Fuel level too high or too low
Pinion or ring gear wom
Fuel tank air vent obstructed
Engine won't turn over: Fuel pump trouble
Valve seizure
Governor link mechanism malfunctioning
Rocker ann seizure
Compression low;
Cylinder, piston seizure
Spark plug loose
Crankshaft seizure
Cylinder head not sufficiently tightened down
Connecting rod small end seizure
No valve clearance
Connecting rod big end seizure
Cylinder, piston worn
Camshaft seizure
Piston ring bad (worn, weak, broken, or sticking)
No fuel flow:
Piston ring/land clearance excessive
Fuel tank air vent obstructed
Cylinder head warped
Fuel pump trouble
Cylinder head gasket damaged
Fuel filter clogged
Valve spring broken or weak
Fuel line clogged
Valve not seating properly (valve bent. wom, Or
Fuel pump relay trouble
carbon accumulation on the seating surface)
Float valve clogged
Other:
Engine flooded:
Igniter trouble
Fuel ~ too high
Engine oil viscosity too high
Float valve wom or stuck open
Front final gear case oil viscosity too higll
Starting technique faulty, (When flooded, crank the
(KAF620A)
engine with the throttle fully opened to allow
Drive train trouble
more air to reach the engine.)
Brake dragging
No spark; spark weak:
Spalk plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap not in good contact Poor Running or No Power at High Speed'
Spark plug incorrect Firing incorrect: '
Igniter trouble Spark plug dirty, broken, or maladjusted
Ignition coil trouble Spark plug cap shorted or not in good contact
Pickup coil trouble Spark plug incorrect
Ignition switch shorted Igniter trouble
Wiring shorted or open Ignition coil trouble
Fuse blown Pickup coil trouble
Compression low: Fuel/air mixture incorrect:
Spark plug loose Choke valve stuck close
Cylinder head not sufficiently tightened down Main jet clogged or wrong size
No valve clearance Fuel level too high or too low
Cylinder, piston wom Air bleed pipe holes clogged
Piston rings bad (wom,:-veak. broken, or sticking) Air cleaner clogged, poorly sealed, or missing
Piston ring/land clearance excessive ' Water or foreign matter in fuel
Cylinder head gasket damaged Fuel tank air vent obstructed
Cylinder head warped Fuel line clogged
 APPENDIX 17-3

Fuel pump trouble Coolant incorrect:

Govemor link mechanism malfunctioning Coolant level too low
Compression low: Coolant deteriorated
Spark plug loose Thick coolant
Cylinder head not sufficiently tightened down Cooling system component incorrect:
No valve clearance Radiator clogged
Cylinder, piston wom Thermostat trouble
Piston ring bad (wom, weak,. broken, or sticking) Radiator cap trouble
Piston ring/land clearance excessive Radiator fan switch trouble
Cylinder head gasket damaged Fan motor broken
Cylinder head warped Fan blade damaged
Valve spring broken or weak Water pump not tuming
Valve not seating-properly (valve bent, wom, or Water pump impeller damaged
carbon accumulation on the seating surface.)
Knocking:
carbon built up in combustion chamber Over Cooling:
Fuel poor quality or incorrect Radiator fan switch trouble
Spark plug incorrect ~1rOUbie
Igniter trouble
Miscellaneous:
Throttle valve won't fully open Converter Operation Faulty:
Brake dragging Belt slipping:
Overheating Belt dirty « worn
Engine oil level too high Drive or driven pulley sheave dirty or wom
Engine oil viscosity too high Driven pulley spring broken or weak
Front. final gear case oil viscosity too high Converter engagement speed too low:
(KAF620A) Drive pullev spring broken or weak
Drive train trouble Converter engagement speed too high:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
Overheating: Drive pulley weight doesn't move smoothly
Firing incorrect: Drive pulley movable sheave doesn't move smoothly
Spark plug dirty, broken, or maladjusted Drive or driven pulley movable sheave bush worn
Spark plug incorrect Drive pulley weight or roller worn
Igniter trouble Shifting too quickly:
Fuel/air mixture incorrect: Drive pulley spring weak
Main jet clogged or wrong size Driven pulley spring weak or incorrectly installed
Fuel level too low (too loose)
carburetor holder loose \ Shifting too slowly:
Air cleaner clogged, poorly sealed, or missing Belt dirty or worn
Compression high: Drive or driven pulley sheave dirtyorwom
carbon built up in combustion chamber Drive pulley weight doesn't move smoothly
Engine load faulty: Drive pulley movable sheave doesn't move smoothly
Engine oil level too high Driven pulley spring incorrect instafled (too tight)
Engine oil viscosity too high Driven pulley movable sheave doesn't move
Drive train trouble smoothly
Brake dragging
Converter and/or belt excessive heating:
Belt dirty or wom Gear Shifting Faulty:
Drive or driven pulley sheave dirty or wom Doesn't go into gear:
Driven pulley spring broken or weak Shift arm bent or seizure
Drive pulley spring broken or weak Gear stuck on the shaft
Idle speed too high Shift cable maladjusted
Converter fan damaged Shift cable lubrication inadequate
Lubrication inadequate: Shift cable damaged
Engine oil level too low Jumps out of gear:
Engine oil poor quality or incorrect Shifter groove wom
Front final gear case overheating (KAF620A): Gear dogs worn
Insufficient oil Shift arm positioning bolt spring weak or. broken
Bevel gears maladjusted Shift block worn
LSD clutch maladjusted Transmission shaft. and/or gear splines wom
Shift cable maladjusted
17-4 APPENDIX

Overshifts: Abnormal Frame Noise:

Shift arm positioning bolt spring weak or broken Shock absorber noise:
Shift cable maladjusted Shock absorber damaged
Brake noise:
Brake linings overwom or wom unevenly
AbnonnaJ Engine Noise: Drum worn unevenly or scored
Knocking: Brake spring(s) weak or broken
Igniter trouble Foreign matter in hub
Carbon built up iii combustion chamber Brake not properly adjusted
Fuel poor quality or incorrect Other noise:
Spark plug incorrect Brackets, nuts, bolts, etc. not properly mounted or
Overheating tightened
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston wom Exhaust Smokes Excessively:
Connecting rod bent White smoke:
Piston pin, piston pin holes wom Piston oil ring wom
Valve noise: Cylinder worn
Valve clearance incorrect Valve oil seal damaged
Valve spring broken or weak Valve guide wom
Camshaft bearing wom Engine oil level too high
Rocker ann push rod runout excessive Black smoke:
Other noise: Air cleaner clogged
Connecting rod small end clearance excessive Main jet too large or fallen off
Connecting rod big end clearance excessive Choke valve stuck closed
Piston ring wom, broken or stuck . Fuel level too high
Piston seizure or damaged Brown smoke:
Cylinder head gasket leaking Main jet too small
Exhaust pipe leaking at cylinder he8d connection Fuel level too low
Crankshaft runout excessive Air cleaner poorly sealed or missing
Engine mounts loose
Crankshaft bearing wom
Loose alternator rotor Handling and/or Stability Unsatisfactory:
Steering wheel hard to turn:
Steering shaft bearing damaged
Abnonnal Drive Train Noise: Steering shaft lubrication inadequate
Converter noise: Steering shaft bent
Beltwom Steering gear assembly damaged
Drive or driven pulley sheave wom Tire air pressure too low
Drive or ~riven pulley movable sheave bush wom LSD clutch maladjusted (KAF620A)
Drive or driven pulley mount loose Noise when turning (KAF620A):
Driven pulley shoe wom Damaged side gear or pinion (Front final gear case)
Drive pulley weight or roller side washer wom Worn clutch friction plate (Front final gear case)
Drive pulley weight or roller wom Worn clutch spring (Front final gear case)
Transmission noise: Steering wheel shakes or excessively vibrates:
Bearings worn Tire(s) wom
Transmission gears wom or chipped Suspension arm bushing wom
Metal chips jammed in gear teeth Tie-rod joint wom
Transmission oil insufficient Wheel rim warped
Final drive noise: . Axle shaft bearing wom
Bearing worn Steering wheel mount loose
Gears worn or chipped Steering bolt or nut loose
Metal chips jammed in gear teeth Steering wheel pulls to one side:
Insufficient lubricant Frame bent
Bevel gears maladjusted {KAF620A) Wheel misalignment
Wom LSD clutch friction plate (KAF620A) Suspension ann bent or twisted
Wom LSD clutch spring (KAF620A) Steering shaft bent
Universal joint damaged Steering gear assembly damaged
Front or rear tire air pressure unbalanced
Shock absorber unbalanced
 APPENDIX 17-5

Shock absorption unsatisfactory:

(Too hard)
Tire air pressure too high
Shock absorber damaged
(Too soft)
Shock absorber oil leaking
Shock absorber spring weak
Tire air pressure too low

Brake Doesn't Hold:

Air in the brake line
Brake fluid leak
Brake fluid deteriorated
Primary or secondary cup trouble
Master or wheel cylinder scratched inside
Brake not property adjusted
Unings overwom or wom unevenly
Drum wom unevenly or scored
Oil, grease on linjng and drum
Dirt water between lining and drum
Overheated brakes

Battery Discharged:
Battery faulty (e.g., plates sulphated, shorted
through sedimentation, electrolyte level too low)
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage)
Ignition switch trouble
Regulator/Rectifier trouble
Altemator trouble
Wiring faulty

Battery Overcharged:
Regulator/Rectifier trouble
. Battery trouble
17-6 APPENDIX
General Lubrication

Lubrication
• Before lubricating each part, clean off any rusty spots with rust remover
and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
o Whenever the vehicle has been operated under wet or rainy
conditions, or especially aher using a high-pressure. spray water,
perform the general lubricant

Pivots and Points: Lubricate with Grease.

Seat Brackets
Cargo Bed Mounting Pins
Throttle lever Pivot
Brake Pedal Pivot
Transmission Shift Control lever Pivot
Differential Shift Cable Upper End
2WD/4WD Shift lever Pivot (KAF620A)
Propeller Shaft Bearing (KAF620A) [A]
o Grease the propeller shaft bearing using the grease nipple [B].

Cables: Lubricate with Rust Inhibitor.

Throttle Cable
Choke Cable
Differential Shift Cable
2WD/4WD Shift Cable (KAF620A)
SpecIal Tool - Pressure Cable Luber: K56019-021

Cables: Lubricate with Motor Oil.

Parking Brake Cables
 APPENDIX 17-7
Nut, Bolt, and Fastener Tightness

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
o Check the engine fastener tightness when the engine is cold (at
room temperature).
*If there are loose fasteners, first loosen by % tum, then retorque them
to the specified torque following the specified tightening sequence.
Refe~ to ~he appropri~e chapter for torque specifications. If torque
specifications are not In the appropriate chapter, see the basic torque
table (see Torque and Locking Agent in the General Information
chapter).
*If cotter pins are damaged, replace them with new ones.

Nut. Bolt. and Fastener to be checked

Engine:
Suspension:
Engine Mounting Bolts
Suspension Arm Pivot Bolts
Exhaust Pipe Holder Nuts
Strut Mounting Nuts
Exhaust Pipe and Muffler Clamp Bolt
Strut Clamp Nuts and Cotter Pins
Muffler Mounting Bolts
Leaf Spring Mounting Nuts
Throttle Level Pivot Clip
Shock Absorber Mounting Nuts
Fuel Tank Holder Nuts
Steering:
Transmission/Final Drive:
Steering Wheel Mounting Nut
Axle Nuts and Cotter Pins
Intermediate Shaft Clamp Bolts
Drive Shaft Bracket Mounting Nuts
Tie-rod End Nuts and Cotter Pins
Transmission Shift Cable Upper End Clip
Tie-rod End Locknuts
Transmission Shift Lever Clamp Bolt
Suspension Arm Joint Nuts and Cotter Pins
Differential Shift Lever Pivot Clip
Steering Gear Assembly Mounting Bolts
Differential Shift Cable Upper End Clip
Main Shaft Bracket Mounting Bolts and Nuts
Differential Shift Lever Mounting Nut
Front Final Gear Case Mounting Nuts (KAF620A)
Frame:
Front and Rear Bar Mounting Bolts and Nuts
Front Final Gear Case Bracket Bolts (KAF620A)
Front Guard Mounting Nuts
Propeller Shaft Bearing Mounting Nuts (KAF620A)
Cargo Bed Hook Mounting Bolts
2WD/4WD Shift Lever Pivot Clip (KAF620A)
Cargo Bed Mounting Pin Clips
2WD/4WD Shift Lever Mounting Nut (KAF620A)
Screen Mounting Nuts
Hi/Low Shift Lever Pivot Clip (KAF620A)
Seat Bracket Nuts
Hi/Low Shift Cable Upper End Clip (KAF620A)
Seat Back Mounting Nuts
Hi/Low Shift Lever Mounting Nut (KAF620A)
Seat Belt Mounting Bolts
Wheels:
Battery Holder Nuts
Wheel Nuts
Skid Plate Mounting Bolts
Brakes:
Rear End Sub-frame Mounting Nuts
Master Cylinder Mounting Bolts
Master Cylinder Push Rod Clevis Pin Clip
Parking Brake Lever Assembly Mounting Bolts
Parking Brake Cable Lower End Clevis Pin Cotter Pins
Brake Pedal Pivot Shaft Cotter Pin
17-8 APPENDIX
Unit Conversion Table

Prefixes for Units: Units of Length:

km x 0.6214 mile
Prefix Symbol Power
m x 3.281 ft
mega M x 1000000 mm x 0.03937 in
kilo k x 1000
centi c x 0.01
milli m x 0.001
micro x 0.00001 Units of Torque:
IJ
N-m x 0.1020 = kg-m
N-m x 0.7376 = ft-Ib
N-m x 8.851 = in-Ib
Units of Mass: kg-m x 9.807 = N-m
kg x 2.205 = Ib
kg-m x 7.233 = ft-Ib
9 x 0.03527 oz kg-m x 86.80 = in-Ib

Units of Volume:
L x 0.2642 = gal (US) Units of Pressure:
L x 0.2200 gal (imp) kPa x 0.01020 kg/cm 2
L x 1.057 = qt (US) kPa x 0.1450 = psi
L x 0.8799 = qt (imp) kPa x 0.7501 = cmHg
L x 2.113 = pint (US) kg/cm2 x 98.07 = kPa
L x 1.816 = pint (imp) kg/cm 2 x 14.22 = psi
mL x 0.03381 = oz (US) em Hg x 1.333 = kPa
mL x 0.02816 = oz (imp)
mL x 0.06102 cu in

UnitsofS~:
km/h x
. 0.6214 = mph
Units of Force:
N x 0.1020 = kg
N x 0.2248 = Ib

kg x 9.807 = N Units of Power:

kg x 2.205 = Ib kW x 1.360 = PS
kW x 1.341 = HP

PS x 0.7355 = kW
PS x 0.9863 = HP

Units of Temperature:

- 40 = OF - 40 = °c
or
-4 32 68 104 176 212 248 284
-40 10 if 20 140
I i I
60 i 80 100:
I 1 I 11
1180 200 1220
:I I: I
240 1 260 280 1 300
I: I Ii
320
I
I
-40
I Ii
-20:
I I: I
o:
I
20 i
:I
40
I I
80
I:
: 100
I I: I I :I I
: 120 . : 140
-17.8 4.4 26. 7 48.9 71.1 93.3 116 138
2

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

(US Model only)

To minimize the noise emissions from this product, Kawasaki has equipped it with effective 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 which results in an
increase in noise level.

LIST OF ABBREVIATIONS
A ampere(s) Ib pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
of degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Q ohm(s)
L liter(s)

Read OWNER'S MANUAL before operating.

 3

Foreword
This MULE 2500 (KAF620C) Service Manual Supplement is designed to be used in conjunction with the
MULE 2510/2520 (KAF620A/B) Service Manual (P/N 99924-1163-01). The maintenance and repair
procedures described in this supplement are only those that are unique to the MULE 2500 (KAF620C). Most
service operations for these models remain identical to those described in the base Service Manual. Complete
and proper servicing of the MULE 2500 (KAF620C) therefore requires both this supplement and the base Service
Manual.

NOTE
o The MULE 2520 (KAF620B) is the base model for the MULE 2500 (KAF620C). Unless otherwise noted, procedures
for the MULE 2500 (KAF620C) are the same as those for the MULE 2520 (KAF620B).

Table of Contents

General Information ........................................................................................................4

Model Identification ...................................................................................................4
General Specifications ................................................................................................5
Cable, Wire, Hose, and Pipe Routing ........................................................................7
Wheels/Tires ...................................................................................................................9
Exploded View ............................................................................................................9
Specifications ...........................................................................................................10
Brakes ............................................................................................................................11
Exploded View ..........................................................................................................11
Steering .........................................................................................................................13
Exploded View ..........................................................................................................1 3
Electrical System ...........................................................................................................14
Exploded View ..........................................................................................................14
Parts Location ...........................................................................................................1 5
Wiring Diagram .........................................................................................................16
 5
General Information (General Specifications)

Item KAF620-C1
Dimensions:
Overall length 2845 mm
Overall width 1 460 mm
Overall height 1 920 mm
Wheelbase 1 870 mm
Track: Front 1 160 mm
Rear 1 180 mm
Ground clearance 170 mm
Seat height 870 mm
Dry weight 501 kg
Curb weight: Front 222 kg
Rear 303 kg
Fuel tank capacity 20 L
Cargo bed (L x W x H) 1 175 x 1 310 x 250 mm
Performance:
Minimum turning radius 3.4m
Engine:
Type 4-stroke, OHV, V2-cylinder
Cooling system Liquid-cooled
Bore and stroke 76.0 x 68.0 mm
Displacement 617 mL
Compression ratio 10.3
Carburetion system Carburetor, Mikuni BV26-18
Starting system Electric starter
Ignition"" system Battery and transistor
Ignition timing 20° BTDC (constant)
Spark plug NGK BMR4A
Cylinder numbering method Front to rear, 1 - 2
Firing order 1 -2
Valve timing:
Inlet: Open: #1 68° BTDC
#2 64° BTDC
Close: #1 76° ABDC
#2 80° ABDC
Duration 324°
Exhaust: Open 94° BBDC
Close 48° ATDC
Duration 322°
Lubrication system Forced lubrication (wet sump)
Engine oil:
Grade SE, SF, or SG class
Viscosity SAE10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 1.8 L
6

Item KAF620-C1
Drive Train:
Primary reduction system:
Type Belt drive torque converter
Reduction ratio 3.5 - 0.98
Transmission gear ratio:
Forward 1.821 (51/28)
Reverse 2.050 (41/20)
Final drive system:
Type Gear (2WD)
Reduction ratio 5.4 (81/15)
Overall drive ratio:
Forward 9.639
Reverse 10.848
Transmission oil:
Type API "GL-5" Hypoid gear oil
SAE90 : above 5°C (41°F)
SAE80 : below 5°C (41°F)
Capacity 2.2 L
Frame:
Type Steel tube. Ladder
Caster (rake angle) 7.5°
Camber 0.8°
Trail 35mm
Tire: Front and rear 22 x 11.00-10. Tubeless
Steering type Rack and pinion
Suspension:
Front: Type MacPherson strut
Wheel travel 100mm
Rear: Type De Dion axle
Wheel travel 70mm
Brake type: Front and rear Drum (Hydraulic)
Parking brake type Drum (Mechanical internal expansion)
Electrical Equipment:
Battery 12 V 19 Ah
Headlight:
Type Sealed beam
Bulb 12 V 35 W x 2
Tail/brake light 12 V 5/21 W x 2
Alternator:
Type Single-phase AC
Rated output 14.7 A @4 000 r/min (rpm). 14 V
Load Capacity:
Maximum vehicle load
(including occupants and cargo) 603 kg
Maximum cargo bed load 363 kg

Specifications are subject to change without notice. and may not apply to every country.
 7
General Information (Cable, Wire, Hose, and Pipe Routing)

1. Horn Button (KAF620B)

2. Install horn button with lead coming rearward.
3. Horn Lead (KAF620B)
4. Main Harness
5. Choke Cable
6. Differential Shift Cable
7. Radiator Fan Motor Breather Hose
8. Brake Light Switch
9. Radiator Fan Leads
10. Radiator Fan Switch Leads
11. Throttle Cable
12. Brake Pipe
13. Transmission Shift Cable
14. Hi/Low Shift Cable (KAF620A)
15. Front Final Gear Case Breather Hose

NOTE : KAF620C is not equipped with the

horn button and horn button lead.

@ Viewed from A
 co
1.110mm NOTE: KAF620C is not equipped with the horn. 15. Main Harness
2. Horn (KAF620B) 16. Battery (-) Leads (Black Tape)
3. Radiator Fan Switch Leads 17. Battery (+) Leads (Red Tape)
4. Brake Light Switch Leads 18. Parking Brake Light Switch Lead
5. Cooling Temperature Warning Light Leads 19. Ground Lead (Engine)
6. Fuel Pump 20. Starter Motor Lead
7. Tape Side
8.100mm
9. Neutral Switch Lead
10. Ground Lead (Frame)
11. 50 mm or More 9
12. Igniter
13. Tape Side
14. Position Mark (White Tape)

(~
I

@
~
~-tIT
@
 9
Wheels/Tires (Exploded View)

T1 : 98 N-m (10.0 kg-m, 72 ft-Ib)

10
Wheels/Ti res (Specifications)

Item Standard Service Limit

Wheel Alignment:
Caster 7.5° (non -adjustable) - - -

Camber O.so (non-adjustable) - - -

Toe-in 0- 20 mm - - -

Tires:
Standard tire 22 x11.00-1 0
Dunlop KTS69A Tubeless - - -
Tire air pressure (when cold):
Front SO kPa (O.S kg/em', 12 psi) - - -

Rear 1S0 kPa (1.S kg/em', 26 psi) - - -

Maximum tire air pressure 250 kPa (2.5 kg/em 2 , 36 psi) - - -

(to seat beads, when cold)

Tire tread depth 13.2 mm 3mm
 11
Brakes (Exploded View)

AD : Apply adhesive agent.

F : Apply brake fluid.
G : Apply grease.

T1 : 5.9 N-m (0.60 kg-m, 52 in-Ib)

T2 : 7.8 N-m (0.80 kg-m, 69 in-Ib)
T3 : 8.8 N-m (0.90 kg-m, 78 in-Ib)
T4: 18 N-m (1.8 kg-m, 13.0 H-Ib)
T5: 25 N-m (2.5 kg-m, 18.0 H-Ib)
T6 : 44 N-m (4.5 kg-m, 33 H-Ib)
17: 195 N-m (20.0 kg-m, 145 H-Ib)

T5

G
12

®
T4,_~
~ ~ Yellow

~~~1
T4

White
 13
Steering (Exploded View)

T1: 20 N-m (2.0 kg-m, 14.5 H-Ib)

T2: 34 N-m (3.5 kg-m, 25 H-Ib)
T3: 39 N-m (4.0 kg-m, 29 H-Ib)
T4 : 49 N-m (5.0 kg-m, 36 H-Ib)
T5 : 52 N-m (5.3 kg-m, 38 H-Ib)

ct T1

\~
@ ~

~\i4)

1 ~

~T~T2
14
.
Electrical System (Ex p loded View)

~
~

L ___________ ..1

! . d ith the horn.

NOTE' KAf620C ;. "M eq·'ppe W ' , . ~~"tb
 15
Electrical System (Parts Location)

Horn (KAF620B)(A]
Radiator Fan Switch [B]
Radiator Fan [C]
Ground Lead (Horn Button, KAF620B) [D]
NOTE
o KAF620C is not equipped with the horn horn button and horn
button ground lead.

Horn Button (KAF620B) [A]

Ignition Switch [B]
Coolant Temperature Warning Light [C]
Light Switch [D]
Brake Light Switch [E]

Ground Lead (Frame) [A]

Regulator/Rectifier [B]
Battery [C]
Parking Brake Light Switch [D]
Igniter [E}
Fuel Pump Relay [F]

Fuses [A]
Starter Circuit Relay [B]

Neutral Switch [A]

Spark Plugs [B]
Coolant Temperature Warning Light Switch [C]
Ignition Coils [D]
Pickup Coils [E]
Starter Motor/Relay [F]
Ground Lead (Engine) [G]
Alternator [H]
Oil Pressure Switch [I]
Fuel Pump [J]
 .,,0',," m """
a.,
Fuel 0)
<D -E".:1<:r1 T, Punp
Relay
------------_·_------------------1
(j) :E¥" I
,., ...:.... ....,.,.:...,.:.,:.'.'...:... :... :... ...:..•.,.,:;
' ~ optlonsl Psrts (for EXSmple)
k:iiD -Beeper -----------------
'

r- - ; ~ B;~
Q) ">0-1'
-f:~1 T , Parking
',i ',' '.,i cstlo,crut",tf
R I
lanltar ReGulatorl
Rlctlfler 2. Socket ~'
iii ~ rrm
3. Hour ..ater
® -C~~
· L .~..~
! .. km!h II 4. "Iper
5.lndlcltor llGhts(ln Spaado.ater)
en
~;;'ih~~g~
IllUIIlnltlon

l3
011 Pressure WarninG
Pllrt Ina Brllke
Coollnt la.Derature Wlrnlna
6. ROOr WOrnlng Light

--- =- 7. CO, gO Bea LIght

COD lonl Tem.oralu ro Iii!'\-- IJ

wornlno L10hl ~WfG--D<l-WfG
-=- n ====::tttttti
- i= ~-"i S ~ ~
~"~
::.:-S~~ I. Horn Button
9. Horn
: 10. AI ternetor
L~~: ~~~! ___________________________ _ -~
::l,
::l
(Q
LIOhl Sw'lch C
iii'
ce
Dl
-3
Tlll/Brllke
lanlt Ion lights
Switch 12Y5121WJ2

Accessor y
Terminals LlG~ Neutral Switch

, ,
Headllohts
12V35W)(2
,, ,,

: BroU LIght
,i Switch
~t-C>D-IRl ==========~
~l-c:KI-

, ................ ·l<HI/T'----------I+I..,
(i) ;',(::"i:II",==================:::":
~ .
":'::' Co I or Code
starter 011 Coolant [gnltlon PiCkup Coils AI ternator Ik Ille.
Rad llltor Fan : Motorl Preuur. TelllPere.ture Colla IL 1111'
Sw'lch Rllu SwitCh Switch
.. I Irown

F~:::::~>==:::::::JI
'- _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . .J
ellnollt,
DG Dirt gnon
Irlln
Gy Ir"
L. Llillt U"
,o ,,-
LG Ullilirun
PIn.
"rll,
H'
Rlt,
'11111

Ignition svltch Connectlona liGht SlIltch Brate LIght Switch connectlona Part Ina Brit, liGht SV Itoh Connlct lonl •• utnt Switch Connect lana

orr
ON When brUt Dldlll Is Dushed down 'ill,n DarUnt brate I,,,r I. Dull.d UD