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When inserting the cotter pin, if the slots in the nut do

1. M 8 7 Crankcase Cover Removal 8 7 Crankcase Cover EE 8 7 Crankcase Cover Installation pp 8 7 Camshatt and Tappets sse ae fte beide d ab i Ee ERE Re fend 8 8 Camshaft Tappet Removal ener 8 8 Camshaft Tappet Installatiom 4 8 8 Camshaft ISAS SEO EE 8 9 Camshaft Assembly ee 8 9 Camshaft Inspection iui ecce tee ette gate geo e dete be PvE La get 8 9 Camshaft Bearing Journal Wear eene then nnne nenne 8 10 Cylinders arnd Pistons oen dumb e utes Gu hah adusta eC orae 8 11 Piston Ve E EE 8 11 Piston Installation i 8 12 Piston Clearilfig to 8 13 Piston Ring and Ring Groove Wear eere ioca 8 14 a ET 8 15 Piston Pin Piston Pin Hole and Connecting Rod 8 15 Piston Diamieter cien i trt D HE 8 16 Cylinder Inside Diameter ee crit ee Eit Reit tl ee CoA pes ERR Ene e tad 8 16 Crankshaft and Connecting EE 8 17 Connecting Rod REMOVAL 0 8 17 CorinectinmgiRGd Installati n E 8 17 Crankshaft Removal pp 8 17 Crankshaf tnstallatlonm 8 17 Gleaning lnsDecllOfi EE 8 17 Connecting Rod Bends Twist eni ree m e te no
2. 16 17 Electrolyte Level Inspection 16 17 Electrolyte Specific Gravity 16 17 Charging Condition Inspection 16 17 Initial Charging 16 18 Ordinary Charging 16 19 Battery Test Charging 16 21 Charging System 16 22 Alternator Rotor and Stator 0 16 22 Alternator Rotor and Stator Installation 16 24 Charging System Operational 16 25 Stator Coil Resistance 16 26 Regulator Rectifier Inspection KAF400 A1 B1 C1 AGF A8F B6F B8F C6F C8F 16 26 Regulator Rectifier Inspection KAFA00A9F B9F C9F 16 28 Ignition System tete 16 30 Spark Plug Removal 16 30 Spark Plug Installation 16 30 Spark Plug Cleaning Inspection 16 30 Spark Plug Gap Inspection 16 30 Ignition Coil Removal 16 30 Ignition Coil Installation 16 31 Ignition Coil inspection 16 31 Electric Starter System 16 33 Starter Motor Remowval 16 33 Starter Motor Installation 16 33 Starter Solenoid Inspection 16 34 Starter Motor Inspection 16 34 Starter Motor
3. einai 10 9 Tire Wear Inspection RN 10 10 10 2 WHEELS TIRES Exploded View 1K02009BW5 C WHEELS TIRES 10 3 Exploded View N Fastener 3orgue Remarks N m kgf m ft lb 1 Wheel Nuts 34 3 5 25 R R Replacement Parts W Apply a soap and water solution or water 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheel Alignment Toe in Tie rod Length Distance Between Flange End and Locknut 0 20 mm 0 0 79 in at 1G about 34 mm 1 34 in Tires Rims Standard Tire KAF400 A C Front Rear KAF400 B Front Rear Rim Size Front Rear Tire Air Pressure when cold Front Rear KAF400 A C KAF400 B Maximum Tire Air Pressure to seat beads when cold Tire Tread Depth 24 x 9 00 10 DUNLOP KT869M Tubeless DURO DI K968M Tubless 24 x 11 00 10 DUNLOP KT869 Tubeless DURO DI K968 Tubless 22 x 9 00 10 DUNLOP KT901 Tubeless 22 x 11 00 10 DUNLOP KT869 Tubeless 10 x 7 0 10 x 8 5 47 kPa 0 47 kgf cm 7 psi 97 kPa 0 97 kgf cm 14 psi 110 kPa 1 1 kgf cm 16 psi 250 kPa 2 5 kgf cm 36 psi 3 mm 0 12 in WHEELS TIRES 10 5 Special Tool Jack 57001 1238 7571238ST C 10 6 WHEELS TIRES Wheel Alignment Toe in is the amount that the front wheels are closer together in front than at the rear at the axle height When there is toe in
4. Front Final Bevel Gear Rear Axle Adjustment 11 20 Rear Axle Installation Bevel Gear 11 26 Axle Differential Gear Inspection 11 26 Dust Boot Inspection Ball Bearing Inspection 11 26 400 11 41 Oil Seal 11 26 Front Axle Joint Boot Bevel Gear Case KAF400 A C 11 27 Replacement KAF400 A C 11 42 Driven Bevel Gear Removal 11 27 Ball Bearing Inspection 11 47 Driven Bevel Gear Installation 11 27 Grease Seal Inspection 11 48 Driven Bevel Gear Disassembly 11 28 11 2 FINAL DRIVE Exploded View KAF400 A C FINAL DRIVE 11 3 Exploded View KAF400 A C No Fastener Torque kgf m 2 Front Final Gear Case Oil Drain Plug 3 Gear Nut 156 6 115 L 4 Pinion Gear Bearing Holder 98 10 72 5 Differential Gear Housing Bolts 49 5 0 36 L 6 Ring Gear Cover Bolts M8 25 2 5 18 7 Ring Gear Cover Bolts M10 47 4 8 35 L 8 Rear Axle Bracket Bolts 40 4 1 30 9 Rear Axle Bracket Flange Bolts 49 5 0 36 G Apply grease GO Apply gear oil for LSD L Apply a non permanent locking agent LG Apply liquid gasket ThreeBond 1215 Gray M Apply mo
5. fr ETE 1 VS BR Ignition D 1 Switch Oil Temperature BR GE Warning Indicator 7 Light 12V1 7W Uc T BK W BK W BR Light Switch Position Light R Brake 12V5W BK Y Light CORE AH ight Switch i15y21 5g Position Light 12V5W BK Y Headlight 12V30W R BK Y Headlight R 12V30W BK Y IGNITION SWITCH CONNECTIONS Color BR BK W W BK BK Y Light Switch Connections 210428 5 ELECTRICAL SYSTEM 16 7 Wiring Diagram KAF400 A C Speed Sensor Option En 1 2 8 8 e 1 1 011 Temperature Sensor BR BR 1 pr T 2 Neutral Switch lt 3 Reverse Switch EUR Oil Temperature Warning Indicator EUR Europe Model Control Unit O 5 Reverse Light 12V15W EUR R W BR v Regulator G W Rectifier BK Y 5 3 5 1 1 1 1 5 5 z 1 1 5 H OI Starter Starter Starter Motor 7 Circuit Circuit Frame Relay Relay Alternator Ground Brake Neutral Terminal Ignition KAF400A9F C9F Models Coil Battery EE d CELL a 12V14Ah Spark Plug 5 Engine S Ground 8 Terminal E Regulator 6 8 Rectifier BK Y L 2 Steering Shaft Steer ine Component Gear Assembly Color BK Black BL Blue PA BR
6. If the battery is not given a full initial charging it will discharge in a few weeks After that it can not be charged by supplemental charging Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typi cally employed at automotive service stations un less the charger rate can be reduced to the level re quired Charging the battery at a rate higher than speci fied may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charg ing rates also cause the plates to shed active mate rial Deposits will accumulate and can cause inter nal shorting If the temperature of the electrolyte rises above 45 C 113 F during charging reduce the charging rate to lower the temperature and increase charg ing time proportionately Remove Battery Filler Caps A WARNING Electrolyte contains sulfuric acid which is harmful to skin eyes and clothing Wear eye protection and rubber gloves If spillage occurs on body or clothing rinse at once with water for at least 15 minutes Battery ELECTRICAL SYSTEM 16 19 e Fill each cell to the upper level line on the battery case with fresh electrolyte specific gravity 1 270 at a temperature of 30 C
7. eee 14 2 ETE 14 4 Special x te e e e e bci v ente d M ede Der dvds 14 5 Steering Wheel and Main Shaft Assembly pp 14 6 Steering Wheel Free Play 1 4 4 eene nin tentes 14 6 Steering Wheel GCentering err reco seis re 14 6 Steering Wheel and Steering Shaft Removal pp 14 6 Steering Wheel and Steering Shaft Installation 14 7 Steering Gear le alten eade Acus e evan 14 8 Steering Gear Assembly 2222 2 1 1 0001 11 1 0 14 8 Steering Gear Assembly 22 01000 14 8 Steering Gear Preload 2 28001 0 14 9 Tie rod Length Adjustment e e ode 14 9 DUSt BOOt INSPECtiO Nea ER 14 9 Steering Knuckles retten e haie 14 10 Steering Knuckle nente tete std 14 10 Steering Knuckle Installation 14 10 Knuckle Bearing ferioval etude tone pec rette tente diee tete ebe 14 11 Knuckle Bearing Installations ceret ten teet ENEE 14 11 Knuckle Joint Removal gett Reeder 14 11 Knuckle Joint me mnm nemen 14 12 14 2 STEERING Exploded View STEE
8. 400 Transmission Case Disassembly Transmission Case Assembly Transmission and Shift Mechanism Transmission Cable Installation Transmission Shift Cable Inspection pp Shift Rod Bending Shift Fork Ear and Shifter Groove Transmission and Shift Mechanism Inspection 2WD AWD Shift Mechanism 400 2WD AWD Shift Cable Adjustment eges 2WD AWD Shift Cable 9 10 9 11 9 12 9 12 9 12 9 13 9 13 9 14 9 15 9 16 9 16 9 20 9 28 9 28 9 29 9 29 9 29 9 30 9 31 9 31 9 31 2WD AWD Shift Cable Inspection 2WD AWD Shift Mechanism 2WD AWD Shift Mechanism Inspection pp Differential Gears and Shift Mechanism Differential Shift Cable Adjustment Differential Shift Cable 4 2 2 Differential Shift Cable Inspection Differential Shift Mechanism Removal emt Differential Shift Mechanism Installation Differential Shift Mechanism Inspection pp Differential Gear Remowval Differential Gear Installation Differential Gear Inspection Bearings and Oil Seal Bearing Replacement
9. A C 1402016895 C TRANSMISSION 9 7 Exploded View No Fastener Torgu Remarks N m kgf m ft Ib 1 Differential Gear Housing Bolts 57 5 8 42 L L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 O Apply engine oil R Replacement Parts 9 8 TRANSMISSION Exploded View KAF400 B TRANSMISSION 9 9 Exploded View No Fastener Remarks N m ft Ib 1 Bearing Holder 137 14 101 L 2 Drive Shaft Nut 137 14 101 MO G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 O Apply engine oil R Replacement Parts 9 10 TRANSMISSION Specifications Item Standard Service Limit Transmission Oil Type API GL 5 Hypoid gear oil Viscosity SAE90 above 5 C 41 F or SAE80 below 5 C 41 F Capacity KAF400 A C 2 4 L 2 5 US qt KAF400 B 2 2 L 2 3 US qt Oil Level Between H and L lines on dipstick Transmission and Shift Mechanism Shift Fork Ear Thickness Shifter Groove Width Reverse Chain 20 link Length 2WD AWD Shift Mechanism KAF400 A C Shifter Block Outside Diameter Shifter Groove Width 5 9 6 0 mm 0 2322 0 23
10. neng en Kawasaki MULE 600 Utility Vehicle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Converter System Engine Lubrication System Engine Removal Installation Engine Bottom End Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System a 0 l gt Appendix MULE 610 4x4 MULE 600 Kawasaki Utility Vehicle Service Manual rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without i
11. 1 Accessory Fuse 10 A 2 Fuse 30A 3 Battery 4 Engine Ground Cable 5 Starter Motor Cable 6 Frame Ground Lead 7 Parking Brake Light Switch 8 Starter Circuit Relay Brake 9 Starter Circuit Relay Neutral 10 Regulator rectifier 11 Temperature Warning Indicator Control Unit KAF400 A C 17 12 APPENDIX Cable Wire and Hose Routing DETAIL C E 7 Ye DETAIL eae K D EnA js 25 50 S Sag RINI q MONS E OA 2 RA P DETAIL Cable Wire and Hose Routing Engine Mounting Bolt Engine Ground Lead 0 2 mm 0 0 08 in Choke Cable Cooling Fan Cover Bands Transmission Shift Cable Throttle Cable Starter Motor Cable Push the cable and change the route 10 mm 0 39 in 20 10 mm 0 79 0 39 100 10 mm 3 9 0 39 Battery KAF400 A1 AAF B1 BAF C1 CAF Models KAFA00ABF ACF BBF BCF Models Engine Ground Lead Bolt APPENDIX 17 13 17 14 APPENDIX Cable Wire and Hose Routing X Section X 1808050884 C Europe Model Rear Brake Panel Breather Hose Main Harness Tail brake Light Leads Reverse Light Leads Clamp Brake Pipe 1 2 3 4 5 6 APPENDIX 17 15 Cable Wire and Hose Routing 52 A lt gt LL gt
12. APPENDIX 17 25 Cable Wire and Hose Routing KAF400 A C 1808041884 C 1 Band 2 Front Final Gear Case Breather Hose 3 Grommet 4 Clamp 5 Front Final Gear Case 17 26 APPENDIX Cable Wire and Hose Routing en X NE 3 9 8 K AS 1 Breather Hose KAF400 A C 2 Brake Hose 3 Clamp 4 Clamp 5 Clamp Bracket 6 Front Guard 7 Grommet 8 Bands 9 Bolt 10 Bracket 11 Knuckle 12 Retainer 13 Brake Pipe 14 Clamp 15 Front Brake Panel 1808042884 C APPENDIX 17 27 Cable Wire and Hose Routing LL 5 1 Cover 2 Band 3 Clamp 4 Clamp 5 Tail Brake Light MODEL APPLICATION This digit in the frame number changes from one machine to another Year Model Beginning Frame No 2005 KAF400 A1 JK1AFEA105B500001 1115 500001 2005 KAF400 B1 V 4AF400BBB600001 2005 KAF400 C1 JK1AFEC105B500001 2006 KAF400A6F JKT1AFEA1D6B507301 1116 502901 2006 KAF400B6F JK1AF400BBB600501 2006 KAF400C6F JK1AFEC106B501901 JK1AFEA107B516301 2007 KAF400A7F K4AF400AAB600001 JK1AFEB107B505651 2007 KAF400B7F yk 1AF400BBB600701 2007 KAF400C7F JK1AFEC1017B504301 JK1AFEA108B537001 2008 KAF400A8F V 4AF400AAB600501 JK1AFEB108B512001 2008 KAF400B8F JK1AF400BBB601001 2008 KAF400C8F JK1AFEC108B509501 JK1AFEA109B542001 2009
13. IP11009BS1 C 15 30 FRAME Guard and Cover Cooling Fan Guard Removal KAF400ABF ACF BBF e Remove Band A Quick Rivets B Tapping Screws C and Collars D Flap E Tapping Screws F Cooling Fan Guard G Cooling Fan Guard Installation KAF400A9F AAF B9F BAF C9F CAF e Installation is the reverse of removal Band A Cooling Fan Guard B Cooling Fan Guard Installation KAF400ABF ACF BBF BCF e Installation is the reverse of removal Guard Plate Removal e Remove Air Ducts A Quick Rivets B e Remove Quick Rivets A Guard Plate B IP11010BS1 C FRAME 15 31 Guard Plate Installation e Install Guard Plate A Quick Rivets B Cap C Air Ducts e Tighten the clamp screws IP11007BS1 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Exploded 16 2 Wiring Diagram KAF400 A C 16 6 Wiring Diagram KAF400 B 16 8 Specifications 16 10 Special Tools 16 11 Parts 16 12 16 14 Electrical Wiring 16 16 Wiring Inspection 16 16 Battery EE 16 17 Battery Removal 16 17 Battery Installation
14. 5 22 Prive Pulley e EE 5 22 Drive Pulley Installation 5 23 e 5 24 Driven Pulley Removal t cot te Ee tester incense PME Rest edu re Renee Ig SERE Ee 5 24 Driven Pulley Disassembly EE 5 24 Driven Pulley Inspection 5 26 Converter Driven Pulley Shoe Inspection pp 5 26 Bushing Installation 5 27 Driven Pulley CIpejd pm 5 27 ondes EE seele 5 28 High Altitude Setting Information 5 29 lee lee TEE 5 29 5 2 CONVERTER SYSTEM Exploded View 1202041845 C A 5 255 9 NP CONVERTER SYSTEM 5 3 Exploded View No Fastener Drive Pulley Bolt Drive Pulley Cover Bolts 23 Spider 275 Weight Pin Nuts Driven Wear Shoe Mounting Screws L Apply a non permanent locking agent R Replacement Parts 5 4 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 5 5 Exploded View No Fastener Torque Remarks Nm kgfm ft lb EAE CAE Later Models iis udi a 3 Converter Case Front Bolts 26 5 20 2 0 14 4 Converter Case Rear Bolts 25 mm 20 2 0 14 5 Converter Case Cover Screws 5 0 0 5 44 in Ib 6 Bracket Bolts 8 8 0 90 78 7 Filter Housing Bolts 20 2 0 14 8 California Model ACF BAF BCF CAF Models 9 KAF400 A1 A9F B1 B9F C1
15. O ZZR w i Oil Temperature Warning Indicator Control Unit Lead KAF400 A C Reverse Switch Lead Connector for option Speed Sensor Lead for option Reverse Switch Europe Model 5522502 Cable Wire and Hose Routing 17 16 APPENDIX 1808037884 C O O00 5 E AN ETE Um 7 LA WIL Run the breather hose between the starter motor and control panel Assembly Clamp Clamp the Breather Tube and Harness gt a E o 0 lt So x 275 e 0 c 6 ba c bi BON gt D 9 0 5 o ZS Oe oz ka On E e EE E o D 59060050 JO I DO oO oO oO CO e Ape gp APPENDIX 17 17 Cable Wire and Hose Routing HI WA t MY AT DETAIL A Section C C 1 Plug 2 Insert the plug until the plug s flange contact on this side 3 Clamps 4 Good 5 Bad 6 Clamps 7 Belt Converter Air Cleaner 17 18 APPENDIX Cable Wire and Hose Routing KAF400 A1 AAF B1 BAF C1 CAF Models Oo go 4 0 m Ro MN SA A Breather 16 Throttle Cable CZ eir EN ian e SRM ag PS XL y SS Fuel Filter 10 Starter Motor Fuel Tank 11 Clamp Bands 12 Carburetor Frame Pipe 13 The distance between the fuel hose end Fuel Hose and protector end is about 70 90 mm Fuel Pump
16. 9 36 TRANSMISSION Differential Gears and Shift Mechanism e Remove Differential Gear Housing Bolts A Final Gear B e Remove Housing A Knock Pin B Side Gear C Spacer D e Remove Retaining Pin A Pinion Gear Shaft B Pinion Gears C e Remove Side Gear A Differential Gear Installation e Apply molybdenum disulfide oil Side Gears Pinion Gears e Apply a non permanent locking agent Differential Gear Housing Bolts e Tighten Torque Differential Gear Housing Bolts 57 N m 5 8 kgf m 42 ft lb TRANSMISSION 9 37 Differential Gears and Shift Mechanism Differential Gear Inspection e Visually inspect the differential gears Replace the gears as a set if either gear is damaged 9 38 TRANSMISSION Bearings and Oil Seal Bearing Replacement e Using a press a puller the oil seal amp bearing remover or the bearing driver set remove the bearings Special Tools Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 e Using a press and the bearing driver set install the new bearings and or new oil seals Special Tool Bearing Driver Set 57001 1129 Ball Bearing Inspection e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing e Turn A each bearing back and forth while checking for roughness or binding roughness or binding is found replace the bearing Needle Bearing
17. Piston Ring Compressor Belt 080 91 75713208T 6 ENGINE BOTTOM END 8 7 Crankcase Cover Crankcase Cover Removal e Remove Engine see Engine Removal Installation chapter Engine Oil drain see Engine Oil Change in the Periodic Maintenance chapter Crankcase Cover Bolts A Crankcase Cover B NOTE Olf the crankcase cover sticks tap lightly with a mallet near the dowel pins C Crankcase Cover Assembly e Install the ball bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Apply grease to 60 volume between seal lips e Install the oil seal B at specified position as shown C Crankcase Cover D 4 0 4 5 mm 0 16 0 18 in Crankcase Cover Installation e Check to see that the dowel pins A are in place on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown Torque Crankcase Cover Bolts 22 N m 2 2 kgf m 16 ft Ib 1104001BS1 C 8 8 ENGINE BOTTOM END Camshaft and Tappets Camshaft Tappet Removal e Drain the oil see Oil Change in the Periodic Maintenance chapter e Remove Crankcase Cover see Crankcase Cover Removal Cylinder Head Cover A e Position the piston TDC at the end of the compression stroke e Remove the lock screws A and the valve clearance ad justing nuts B which install the rocker arm C and pull the rocker arm off the push rods D e Remove
18. x ee 95 15 6 FRAME Exploded View KAF400 A1 A9F B1 B9F C1 C9F Models Exploded View FRAME 15 7 1 400 1 1 1 AGF A8F B6F B8F C6F C8F Models 2 KAFA00A9F B9F C9F Models AD Apply adhesive agent G Apply grease L Apply Locktite 242 Blue 15 8 FRAME Exploded View KAF400AAF ACF BAF BCF CAF Models Exploded View FRAME 15 9 1 KAFA00ABF ACF BBF BCF Models AD Apply adhesive agent G Apply grease L Apply Locktite 242 Blue R Replacement Parts 15 10 FRAME Exploded View KAF400 C1 C9F Models KAF400 C 15 11 Exploded View 1 Cargo Bed Liner G Apply grease L Apply Locktite 242 Blue 15 12 FRAME Exploded View KAF400CAF Model 15 13 Exploded View 1 Cargo Bed Liner AD Apply adhesive agent G Apply grease 15 14 FRAME Seat and Seat Belts Seat Removal e Remove Seat Bracket Nuts A Seat Brackets B Seat C e Remove KAF400 A1 A9F B1 B9F C1 C9F Models Seat Back Mounting Nuts A Seat Back B KAF400AAF ACF BAF BCF CAF Models Seat Back Mounting Nuts A Seat Back B Seat Installation e Replace the seat back mounting nuts with new ones e Grease Seat Bracket Inside Surfaces A e Touch the bracket B to the stopper C on the frame e Tighten each nut FRAME 15 15 Seat and Seat Belts
19. E uua tact area Be sure to maintain proper alignment and use dai d smooth movements when installing gt 68020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is N absolutely necessary Replace with new ones whenever m removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting RSs pressure on the correct bearing race as shown 2 B Bh B Pressing the incorrect race can cause pressure between Ic 5 A the inner and outer race and result in bearing damage 77 orem 68020188 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed d Press new seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing NS St 68020198 Apply specified grease to the lip of seal before installing the seal Grease 6802046851 C Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation 68020268 5 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri ERN cation points are called out throughout this man
20. Front Final Gear Case KAF400 A C FINAL DRIVE 11 23 Ring Gear Right Shims Ring Gear Left Shims Thickness Part Number Thickness Part Number 0 75 mm 0 0295 in 92180 1254 1 75 mm 0 0689 in 92180 1231 0 80 mm 0 0315 in 92180 1255 1 80 mm 0 0709 in 92180 1232 0 85 mm 0 0335 in 92180 1256 1 85 mm 0 0728 in 92180 1233 0 90 mm 0 0354 in 92180 1257 1 90 mm 0 0748 in 92180 1234 0 95 mm 0 0374 in 92180 1258 1 95 mm 0 0768 in 92180 1235 1 00 mm 0 0394 in Primary 92180 1259 2 00 mm 0 0787 in Primary 92180 1236 1 05 mm 0 0413 in 92180 1260 2 05 mm 0 0807 in 92180 1237 1 10 mm 0 0433 in 92180 1261 2 10 mm 0 0827 in 92180 1238 1 15 mm 0 0453 in 92180 1262 2 15 mm 0 0846 in 92180 1239 1 20 mm 0 0472 in 92180 1263 2 20 mm 0 0866 in 92180 1240 1 25 mm 0 0492 in 92180 1264 2 25 mm 0 0886 in 92180 1241 Pinion Gear Shims Thickness Part Number 1 82 mm 0 0717 in 92180 1219 1 88 mm 0 0740 in 92180 1220 1 94 mm 0 0764 in 92180 1221 2 00 mm 0 0787 in Primary 92180 1222 2 06 mm 0 0811 in 92180 1223 2 12 mm 0 0835 in 92180 1224 2 18 mm 0 0858 in 92180 1225 11 24 FINAL DRIVE Front Final Gear Case KAF400 A C Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the pinion gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly s
21. 86 F or less Let the battery stand for about 30 minutes before charging NOTE Olf the electrolyte level drops add electrolyte to the upper level line before charging e Set the charging rate at 1 10 the battery capacity and charge it for 10 hours For example if the battery is rated at 14 Ah the charging rate would be 1 4 Ah e Turn the charger off then disconnect it from the battery e Check Electrolyte Level see Electrolyte Level Inspection e Tighten the filler caps Ordinary Charging A DANGER Batteries produce an explosive gas mixture of hy drogen and oxygen that can cause serious injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This proce dure prevents sparks at the battery terminals which could ignite any battery gases NOTICE Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typi cally employed at automotive service stations un less the charger rate can be reduced to the level re quired Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting H
22. A Rear Bar Mounting Bolts B Rear Bar C Rear Bar Installation e Replace the front bar mounting nuts and the rear bar mounting nuts with new ones e Tighten Torque Front Bar Mounting Bolts Upper A 44 N m 4 5 kgf m 32 ft Ib Rear Bar Mounting Bolts L 16 mm B 44 N m 4 5 kgf m 32 ft Ib Rear Bar Mounting Bolts L 20 mm C 44 N m 4 5 kgf m 32 ft Ib Washers D Nuts E IPO5001BS1 FRAME 15 25 Front Fender Front Fender Installation e Install Front Fender A Tapping Screw B Hexagon Head Tapping Screw C Collars D Well Nut E Headlight Cover F Screws G Washers H IPO6002BS2 C 15 26 FRAME Guard and Cover Front Guard Removal e Remove Screws A and Collars Front Cover B e Remove Bolts A Clamp Brackets B Front Guard C Front Guard Installation e Install Front Guard A Clamp Brackets B Bolts C Dampers D see Exploded View Front Cover E Screws F and Collars G Floor Center Panel Removal e Remove Center Cover see Center Cover Removal Tapping Screws A Front Center Panel B 1 118011 IP11008BS2 C FRAME 15 27 Guard and Cover Floor Center Panel Installation e Install Front Center Panel A Tapping Screws B Throttle Pedal Bracket C Throttle Pedal Stop Bolt D see Full Throttle Pedal Po sition Adjustment in the Fuel System chapter Locknut E Front Fin
23. Ball Bearing Inspection Needle Bearing Inspection Oil Seal Inspection Transmission Sectional Figure 9 32 9 32 9 32 9 33 9 33 9 33 9 34 9 34 9 35 9 35 9 36 9 37 9 38 9 38 9 38 9 38 9 38 9 39 9 2 TRANSMISSION Exploded View TRANSMISSION 9 3 Exploded View 1 Differential Shift Cable 2 Transmission Cable 3 2WD AWD Shift Cable KAF400 A C 4 KAF400 A1 A9F B1 B9F C1 C9F Models R Replacement Parts 9 4 TRANSMISSION Exploded View TRANSMISSION 9 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Transmission Cable Holder Bolts 42 4 2 31 2 Connecting Plate Bolts M8 28 2 9 21 E 3 Connecting Plate Bolts M10 55 5 6 41 L 4 Transmission Case Bolts 8 8 0 90 78 5 Speed Sensor Cap Bolt 8 8 0 90 78 in lb 6 Transmission Drain Plug 15 1 5 11 7 Cover Screws 4 0 0 40 35 in Ib 8 Oil Line Plug 9 8 1 0 87 in lb L 9 Shift Shaft Lever Bolt 14 1 4 10 10 Differential Shift Cable Holder Bolts 8 90 78 in Ib 11 Bolt except Europe Model 11 78 inib 14 18 ml L Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Liquid Gasket TB1216B 92104 1064 M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts 9 6 TRANSMISSION Exploded View
24. Brown DG Dark Green G Green LB Light Blue 0 orange Pink Brake Light Switch Connections Parking Brake Light Switch Connections Purple i Ground R H When parking brake lever is pulled up 98052 0103E 0197D 0426A 0428A When brake pedal is pushed down W2RO428AW5 C 16 8 ELECTRICAL SYSTEM Wiring Diagram KAF400 B Speedometer Accessory Option Connector Parking Power Outlet Brake Light Hour TERI 12V120W Switch 3 Meter ne NS a gt lt D p e 25 Parking Brake Indicator Light d Se S 12V1 7W Lk 5 Fuse mw oom CD Ignition 6 Switch L 1 9 GE 5 Ex BK Y zE e a Light Switch m X lt BR L BL _ lt BL Lr Guay Brake Light Brake Tail gt Light Switch 15y5 5g Position Light 12V5W Headlight R 12V30W BK Y Position Light R 12V5W BK Y Headlight R 12V30W BK Y IGNITION SWITCH CONNECTIONS Color BR w BK W BK BK Y Light Switch Connections poer o IMEC START Cem C W2L0427AW5 C Wiring Diagram KAF400 B ELECTRICAL SYSTEM 16 9 Speed Sensor Option BK Y 1 7 1 y G G i BR BR ayes l 1 Neutral Switch 2 Reverse Switch EUR EUR Europe Model
25. C9F Models 10 KAF400AAF BAF CAF Later Models 11 KAF400AAF BAF CAF Early Models G Apply grease LT Apply a non permanent locking agent LOCTITE 243 to the threads LG Apply liquid gasket TB1215 92104 1065 KAF400AAF BAF CAF Later Models 5 6 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt Belt Deflection 22 32 22 44 0 87 1 73 in 0 87 1 26 in Belt Width 26 1 27 3 mm 25 2 mm 0 99 in 1 03 1 07 in Drive Pulley Cover Bushing Inside Diameter Sheave Bushing Inside Diameter Spring Free Length Shoe Side Clearance 28 005 28 089 mm 1 103 1 106 in 35 002 35 087 mm 1 378 1 381 in 72 mm 2 83 in 0 05 0 20 mm 0 0020 0 0079 in 28 3 mm 1 114 in 35 3 mm 1 390 in Driven Pulley Movable Sheave Bushing Inside Diameter Spring Free Length Wear Shoe Width 38 016 38 100 mm 1 497 1 500 in 105 mm 4 13 in 38 3 mm 1 51 in 1 9 mm 0 075 in Special Tools Outside Circlip Pliers 57001 144 7570144ST C Bearing Driver Set 57001 1129 7571129ST C Flywheel amp Pulley Holder 57001 1605 1 ST571605ST C Drive Pulley Puller Bolt 57001 1429 875714295 6 Pulley Holder Attachment 57001 1472 75714728T C CONVERTER SYSTEM 5 7 Drive Pulley Holder 57001 1620 875716205 6 Drive Pulley Wrench 57001 162
26. Left Side Cover see Frame chapter Parking Brake Cable End s A Rear Brake Drum see Brake Drum Removal e Remove Collar Brake Panel Mounting Bolts A Brake Panel Assembly B Brake Panel Assy Installation for Front Brake Panel e Clean the mating surface of the brake panel and steering knuckle e Apply liquid gasket to the mating surface A of the steer ing knuckle except bolt holes KAF400 A C Sealant ThreeBond 1215 Gray Brake Panel Assemblies BRAKES 12 15 for Rear Brake Panel e Clean the mating surface of the brake panel and drive shaft bracket e Apply liquid gasket to the mating surface A of the drive shaft bracket except bolt holes KAF400 A C Sealant ThreeBond 1215 Gray e Install Brake Panel Assembly Collar OFor rear oollar installation face the stepped side A to inside B e Apply a non permanent locking agent to the brake panel mounting bolts Bond Loctite 242 Blue e Tighten Torque Brake Panel Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Install Parking Brake Cable End s for Rear Brake Panel e Bleed the brake line after brake drum installation see Brake Line Air Bleeding in this chapter e Be sure to check the brake system for good braking power no brake drag and no fluid leakage WARNING After servicing it takes several applications of the brake pedal before the brake shoes contact the drum which could result in increased stopping
27. Parking Brake Lever Travel Adjustment pp 12 21 Parking Brake Cable 12 21 Parking Brake Lever Rerroval o rigor uentris ond 12 21 Parking Brake Lever Installation pp 12 21 BRAKES 12 3 Exploded View Torque No Fast Remarks SE N m kgf m ft lb Push Rod Locknut Master Cylinder Reservoir Cap 30 in lb Reservoir Clamp Bolt 55 Master Cylinder Mounting Bolts 18 Piston Stop Bolt 78 Brake Pipe Nipples Brake Hose Banjo Bolts rent ste Nuts i5 9 Bleed vaes Ja 080 Lasep Breather Fitting KAF400 A C 12 Front Brake Panel Mounting Bots 3 35 25 t 3 Grommet KAF400 A C is Grease Seal KAF400 A C 15 Breather Hose KAF400 A C 16 400 1 A9F B1 B9F C1 C9F Models AG Apply lithium grease NLGI Grade No 2 G Apply grease L Apply a non permanent locking agent R Replacement Parts 12 4 BRAKES Exploded View Rear Brake BRAKES 12 5 Exploded View Torque No Fastener em kgfm ftlb Remarks 1 Brake Pipe Nipples 18 1 8 13 25 18 3 Bleed Valves 7 8 0 80 69 in Ib A Wheel Cylinder Mounting Bolts 12 0 2 106 Breather Fitting KAF400 A C 6 0 0 61 53 in lb Rear Brake Panel Mounting Bolts 34 3 5 25 L Rear Axle Nuts 304 31 224 Parking Brake Lever Mounting Bolts 25 2 5 18 9 Breather Hoses KAF400 A
28. Sorbers have 5 positions so that the springs can be adjusted for different terrain and loading conditions If the spring ac tion feels too soft or too stiff adjust it in accordance with the following table Spring Action Spring Position Setting Load Terrain Speed Force 1 Soft Light Smooth Low 2 1 1 1 3 STD 4 5 Strong Hard Heavy Rough High e Turn the adjusting sleeve on each rear shock absorber to the desired position with the wrench A Special Tool Steering Stem Nut Wrench 57001 1100 OBoth adjusting sleeves left and right must be turned to the same relative position WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Be sure the adjusters are set equally 13 8 SUSPENSION Struts and Rear Shock Absorbers Rear Shock Absorber Removal e Remove Rear Wheel see Wheels Tires chapter e Remove Rear Shock Absorber Mounting Bolts and Nuts A while moving the frame up or down with a jack Rear Shock Absorber B Rear Shock Absorber Installation e Install the rear wheel temporarily and ground it to load the suspension e Tighten Torque Rear Shock Absorber Mounting Nuts 54 N m 5 5 kgf m 40 ft Ib Rear Shock Absorber Inspection Visually inspect the shock absorber for breaks or distor tion x If the shock absorber is damaged in any way replace it e Check for oil leakage at
29. Standard 14 0 14 2 mm 0 551 0 559 in Service Limit 14 3 mm 0 563 in 6004040281 C 1J08002BS1 C Differential Gears and Shift Mechanism TRANSMISSION 9 33 Differential Shift Cable Adjustment e Put the shift lever A in the UN LOCK position e Install the differential shift cable A to the shift shaft lever B and cable holder C e Put the shift lever A in the LOCK position e Push the shift shaft lever A to the forward LOCK posi tion and make the engagement of the shifter maximum while turning the drive shaft B by hand e Turn the nut C with fingers and pull slightly the inner cable and tighten the nut D e Put the shift lever in the UN LOCK position e Confirm to return the shift shaft lever to UN LOCK posi tion Differential Shift Cable Lubrication Whenever the shift cable is removed lubricate the cable as follows e Apply a thin coating of grease to the cable ends OThe cable may be lubricated by using a pressure cable lubricator with an aesol cable lubricant 6004011481 C 9 34 TRANSMISSION Differential Gears and Shift Mechanism Differential Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely A within the cable housing the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable 6004040281 Differential Shift Mechanism Removal e Remove
30. Transmission Case splitting see Transmission Case Disassembly Differential Gear A e Remove Shift Shaft Stop Bolt A Differential Shift Shaft Nut B Differentia Shift Shaft Lever C and Spring D e Pull up the differential shift shaft A e Remove Shifter B e Remove Differential Shift Shaft A TRANSMISSION 9 35 Differential Gears and Shift Mechanism Differential Shift Mechanism Installation e Install Differential Shift Shaft A Shifter B Shift Shaft Stop Bolt C e Tighten Torque Shift Shaft Stop Bolt 8 8 0 90 kgf m 78 in Ib 1409002851 C e Align the mark A on the shaft with the mark B on the lever as shown e Tighten Torque Differential Shift Shaft Nut 20 N m 2 0 14 ft Ib 109003851 C Differential Shift Mechanism Inspection e Visually inspect Splines on Drive Shaft A Splines on Shifter B Dogs on Shifter Shifter Groove Shift Shaft Pin C Dogs on Differential Gear Housing D 1409004851 C x If they are damaged or worn excessively replace them Shift Shaft Pin Diameter A Standard 8 4 8 6 mm 0 331 0 339 in Service Limit 8 3 mm 0 327 in Shifter Groove Width B Standard 9 0 9 1 mm 0 354 0 358 in Service Limit 9 2 mm 0 362 in 1409005851 C Differential Gear Removal e Remove Transmission Case split see Transmission Case Dis assembly Differential Gear Assembly A
31. Valve Spring Free Length Standard 35 mm 1 38 in Service Limit 32 6 mm 1 28 in Valve Head Thickness e Measure the thickness A of the valve head x If the valve head thickness is less than the service limit replace the valve with a new one Valve Head Thickness Standard 0 7 mm 0 028 in Service Limit 0 4 mm 0 016 in Valve Stem Bend e Place the valve in V blocks at each end of the stem and set a dial gauge A on the stem at a point halfway be tween the blocks Turn the valve to measure the bend The difference between the highest and the lowest dial readings is the amount of bend xlf the valve stem bend is greater than the service limit replace the valve with a new one Valve Stem Bend Standard Less than 0 01 mm 0 0004 in TIR Service Limit TIR 0 05 mm 0 0020 in Valve Stem Diameter e Measure the diameter of the valve stem A in two di rections at right angles at four different positions on the stem If any single measurement is less than the service limit replace the valve with a new one Valve Stem Diameter Standard Inlet 6 960 6 975 mm 0 2740 0 2746 in Exhaust 6 945 6 960 mm 0 2734 0 2740 in Service Limit Inlet 6 95 mm 0 274 in Exhaust 6 93 mm 0 273 in GF06060381 C 8 15011151 C GE15011281 C KE05008BS1 Valves ENGINE TOP END 4 17 Valve Guide Inside Diameter e Measure the inside dia
32. and Cable End B 2WD AWD Shift Cable Holder C and Cable End D KAF400 A C Neutral Switch Lead Connector E Reverse Switch Lead Connector Europe Model Hold the transmission case on a stand or jack Loosen Rear Axle Bracket Flange Bolts A Left and Right e Remove Rear Axle Bracket Bolts B Left and Right 9 14 TRANSMISSION Transmission Case e Remove Connecting Plate Bolts A and Washers Connecting Plate B e Lift up the transmission case until the axle bracket is re moved e Remove Rear Axle Bracket Bolts Left and Right Rear Axles and Rear Axle Bracket Assemblies A Left and Right e Remove Transmission Case A Transmission Case Installation e Hold the transmission case on a stand or jack and hold it e Install Rear Right Axle and Rear Axle Bracket Assembly A Rear Axle Bracket Flange Bolts temporarily e Set the differential shift lever B to differential lock po sition and install the rear left axle and rear axle bracket assembly C e Install Rear Axle Bracket Bolts temporarily 1J05002BS2 Transmission Case TRANSMISSION 9 15 e Apply a non permanent locking agent Connecting Plate Bolts M10 A Connecting Plate Bolts M8 B e Install the washer and tighten the connecting plate bolts M10 and 8 lightly by hand e Install the assembly jig and tighten the bolts see Engine Installation in the Engine Removal Installati
33. arm within its operating angle e Tighten Torque Front Suspension Arm Pivot Bolts 88 N m 9 0 kgf m 65 ft Ib Front Suspension Arm Joint Nut 78 N m 8 0 kgf m 58 ft lb e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the joint tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slit goes past the nearest hole e Bend the cotter pin A over the nut B Front Suspension Arm Inspection e Visually inspect the front suspension arm A for breaks or distortion the front suspension arm is damaged in any way re place it e Check the rubber bushings B in the pivots Replace any bushings that are worn cracked hardened or otherwise damaged 050008 5 HJ07007BS1 9704109851 C 1405001851 C SUSPENSION 13 11 Swingarm Swingarm Removal e Remove Cargo Bed see Frame chapter Transmission Case see Transmission chapter Engine see Engine Removal Installation chapter Brake Pipes A see Brakes chapter Retainer B e Remove Bolt A and Nut Swingarm Rod B e Remove Bolt A and Connecting Wire B Cotter Pin C Nut D and Washer e Install a suitable nut A on the swingarm joint B and tap the nut to free the joint from the frame C e Remove Swingarm D Swingarm
34. e Apply a non permanent locking agent to the pinion gear nut D e Tighten the pinion gear nut so that the stepped side E faces outward Torque Pinion Gear Nut 156 N m 16 kgf m 115 ft Ib 11040118581 C 11 20 FINAL DRIVE Front Final Gear Case KAF400 A C Front Final Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load the pinion gear must be properly pre loaded Also the backlash distance one gear will move back and forth without moving the other gear and tooth contact pattern of the bevel gears must be correct to pre vent the gears from making noise and being damaged Above three adjustments are of critical importance and must be carried out following the correct sequence and method e When any one of the backlash related parts are replaced or the pinion gear nut is loosened even if the purpose is not to replace the parts check and adjust the pinion gear preload the bevel gear backlash and tooth contact by replacing shims e The amount of backlash is influenced by the ring gear position more than by the pinion gear position e Tooth contact location is influenced by pinion gear posi tion more than by ring gear position Pinion Gear Preload Adjustment e Check and adjust the pinion gear preload in the following cases OWhen any of the parts listed below are replaced with new ones Pinion Gear Shims Ball Bearings e Install the pi
35. e Disassemble the wheel cylinder e Check that there are no scratches rust or pitting on the inside of the cylinder A and on the outside of the piston B xIf the cylinder or piston shows any damage replace the wheel cylinder e Inspect the cups C cup is worn damaged softened rotted or swollen replace the wheel cylinder x If fluid leakage is noted at the dust seals the wheel cylin der should be replaced to renew the cup e Check the dust seals D for damage x If they are damaged replace the wheel cylinder e Check the spring E for any damage x If the spring is damaged replace the wheel cylinder Brake Shoe Lining Wear e Refer to Brake Wear Inspection in the Periodic Mainte nance chapter 12 20 BRAKES Brake Panel Assemblies Brake Shoe Spring Inspection e Visually inspect the brake shoe springs A and linkage springs B for breaks or distortion x If the springs are damaged any way replace them Grease Seal Replacement KAF400 A C e Remove Brake Panel Assembly see Brake Panel Assy Removal Bleed Valve Breather Fitting Grease Seal A Be careful not to damage the brake panel when re moving the grease seal Do not remove the cable bracket bolt B e Install the grease seal A to specified position as shown Top Surface of Grease Seal B Center Bottom of Brake Panel C 6 2 7 0 mm 0 24 0 27 in D NOTE Olf the following special tool Grease Seal Driver
36. the fuel pump mounting angle and the shape of the fuel pump bracket are different Fuel Pump Installation e Install Fuel Pump Fuel Pump Mounting Bolts NOTE OFor KAF400ABF ACF BBF models the fuel pump mounting angle and the shape of the fuel pump bracket are different e Tighten Torque Fuel Pump Mounting Bolts 5 4 N m 0 55 kgf m 48 in lb e Install Fuel Hose Fuel Tap Side A Vacuum Hose B Fuel Hose Carburetor Side C Clamps D Fuel FUEL SYSTEM 3 25 Fuel Pump Inspection e Remove the fuel pump see Fuel Pump Removal the hose connection areas A of the fittings are dam aged replace the fuel pump e Blow the air to the outlet fitting A and make sure does not flow the blown air from the inlet fitting B x If the fuel pump does not operate as described replace it with a new one e Inhale the air to the inlet fitting A and make sure does not inhale the blown air from the outlet fitting B x If the fuel pump does not operate as described replace it with a new one 3 26 FUEL SYSTEM Fuel Filter Fuel Filter Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Refer to Fuel Filter Replacement in the Periodic Mainte
37. x If the coil has normal resistance but the voltage inspect showed the alternator to be defective then the rotor mag nets have probably weakened and the rotor must be re placed Regulator Rectifier Inspection KAF400 A1 B1 C1 A6F A8F B6F B8F C6F C8F e Remove the regulator rectifier A Rectifier Circuit Test e Check the resistance in both directions between the ter minals following the table W G W1 W G W2 BK Y G W1 BK Y G W2 The resistance should be low in one direction and more than ten times as much in the other direction If any two terminals are low or high in both directions the rectifier is defective and must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to the first 1 2 of the scale Tester Connection Regulator Circuit Test e Prepare testing tools Test Light Bulb rated 12 V and 3 6 W with socket and leads Batteries Three 12 V batteries Test Leads Four auxiliary leads NOTICE The test light limits the current flow through the reg ulator rectifier Do not use an ammeter or multime ter in its place G W2 1909001851 Charging System ELECTRICAL SYSTEM 16 27 Regulator Circuit Test 1st Step e Connect the test light and the 12 V battery to the regula tor rectifier as shown e Check G W1 and G W2 terminals respectively
38. 0 6214 mile mega M x 1000 000 GE OWNED kilo k x 1 000 mm x 0 03937 in centi C x 0 01 milli m x 0 004 Units of Torque micro 0 000001 uno 2 2 55 x 0 7376 ftlb Nm x 8 851 Units of Mass 9 807 N m kg x 2 205 Ib kgf m x 7 233 9 0 03527 02 86 80 Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgf cm x 9807 kPa L x 2 113 pint US kgf cm 14 22 psi L x 1 816 pint IMP cmHg x 1333 mL x 0 03381 oz US mL x 0 028146 oz IMP Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N kW x 1 360 PS N HUMANO cmo 21 kW x 1344 HP x 0 7355 209 lt dB PS x 09863 Units of Temperature ERO PE QUESO 32 68 104 176 212 248 284 40 20 10 20 40 60 80 100 120 140 160 1180 200 1220 240 260 280 300 320 40 ai 40 i am 110 420 140 160 17 8 44 26 7 48 9 714 933 116 138 SS PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Agent Specifications Special Tools be Periodic Maintenance Procedures Fuel Thr
39. 2 76 3 54 in short side Vacuum Hose 14 Plug Side Fuel Hose 15 Install the vacuum hose to this side APPENDIX 17 19 Cable Wire and Hose Routing KAF400ABF ACF BBF Models 1 2 3 4 5 6 7 8 9 9 9 3 p Papa A HA dr De 1 LZ t du 7 TAW be SEN i GoT 5 g ONRAN oO si 225 Sr of wat 1808262884 C Fuel Filter 10 Starter Motor Fuel Tank 11 Clamp Bands 12 Carburetor Frame Pipe 13 The distance between the fuel hose end Fuel Hose and protector end is short side Fuel Pump 14 Plug Side Vacuum Hose 15 Install the vacuum hose to this side Fuel Hose 16 Throttle Cable Breather 17 20 APPENDIX Cable Wire and Hose Routing California Model 400 1 AAF B1 BAF C1 CAF STR CP CE E T Gs a E Hi A Mit Eris re 2 al V CRI Oe P Pa 1 2 i A CO XE C Je N 79 WSO EI gt SE Kaes LG Fh ODAT e AU 16445 alae APPENDIX 17 21 Cable Wire and Hose Routing Fuel Filters Fuel Tank Bands Frame Pipe Fuel Hose Fuel Pump Vacuum Hose Fuel Hose Breather 10 Starter
40. 25 2 mm 0 99 in 22 44 mm 0 87 1 73 in 1 9 mm 0 75 in Engine Lubrication System Engine Oil Type Viscosity Capacity Oil Level API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE10W 40 0 85 L 0 9 US qt when filter is not removed 1 4L 1 5 US qt when filter is removed Between H and L marks on dipstick Transmission Transmission Type API GL 5 Hypoid gear oil Viscosity SAE90 above 5 C 41 F or SAE80 below 5 C 41 F Capacity A 2 41 2 5 US qt 2 2 L 2 3 US qt Oil Level Between H and L level lines Wheels Tires Tire Tread Depth Standard Tire Front Rear Final Drive A C Front Final Gear Case Oil Type Viscosity A C 24 x 9 00 x 10 DUNLOP KT869M Tubeless DURO DI K968M Tubeless B 22 x 9 00 x 10 DUNLOP KT901 Tubeless A C 24 x 11 00 x 10 DUNLOP KT869 Tubeless DURO DI K968 Tubeless B 22 x 11 00 x 10 DUNLOP KT869 Tubeless GL 5 or GL 6 hypoid gear oil for LSD Limited Slip Differential gears SAE90 GL 6 or SAE140 GL 5 2 10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Capacity 0 35 L 0 37 US qt Oil Level Filler opening level Brakes Brake Fluid Type DOT3 Fluid Level Between upper and lower level li
41. 2V15W EUR Light 6 A 3 m lt N S8 68 38 Starter Motor Alternator Ignition Coil Spark Plug E Starter Circuit Relay Brake Frame Ground Terminal Battery 12V14Ah Engine Ground Terminal Shaft Steering Gear Assembly Brake Light Switch Connections Steering Component Parking Brake Light Switch Connections BR H Regulator Rectifier BK Y Starter Circuit Relay Neutral KAF400B9F Models Regulator Rectifier BK Y EE 4 Color Code Black Brown Chocolate gt ark Green Green G Y Gray LB Light Blue LG Light Green 0 Orange Pim PU Purple BK BL BR 26 e ey LB When brake pedal is pushed down EN BL Terminal Ground O When parking brake lever is pulled up 98052 01046 01186 0427 04294 Red White Y Yellow W2RO427AW5 C 16 10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity Electrolyte Level Specific Gravity 12 V 14 Ah Between upper and lower levels 1 270 20 68 F Charging System Regulator Rectifier Output Voltage Alternator Stator Coil Resistance Battery Voltage 15 V 0 3 or less Ignition system Ignition Coil Air Gap betwee
42. 3 2 3 6 3 7 3 7 3 7 Carburetor Disassembly Carburetor Assembly Carburetor Cleaning Carburetor Inspection Pilot Screw Setting Air Cleaner esses Air Cleaner Element Removal Air Cleaner Element Installation Air Cleaner Element Cleaning Air Cleaner Housing Remowval Air Cleaner Housing Installation Air Cleaner Housing Dust and or Water Installation Fuel PUMP pp Fuel Pump Removal Fuel Pump Installation Fuel Pump Inspection Euel Eilter Fuel Filter Fuel Filter Installation Fuel Filter Inspection Fuel Tank Fuel Tank Fuel Tank Installation Fuel Tank Cleaning Inspection Evaporative Emission Control System California Model KAF400ABF ACF BBF BCF US and Canada MOC GIS seo t tpe edt Parts Removal Installation Hose Inspection Canister Inspection 3 29 3 29 3 29 3 29 3 2 FUEL SYSTEM Exploded View 1602003815 C FUEL SYSTEM 3 3 Exploded View Torque No Fastener ftlb Remarks Air Cleaner Housing Bolts 17 1 7 12 1 i m 22 Ev Bolts
43. B6F B9F Frame Type Caster Rake Angle Camber Trail Tire Front Rear Rim Size Front Rear Steering Type Suspension Front Type Wheel travel Rear Type Wheel travel Brake Type Front and Rear Parking brake type Electrical Equipment Battery Headlight Type Bulb Brake Tail Light Reverse Light EUR Alternator Type Rated output Load Capacity Maximum Vehicle Load Including Occupants and Cargo Maximum Cargo Bed Load Steel tube Ladder 8 1 40 mm 1 57 in 33 mm 1 30 in 24 x 9 00 10 Tubeless 22 x 9 00 10 Tubeless 24 x 11 00 10 Tubeless 22 x 11 00 10 Tubeless 10 x 7 0 10 x 8 5 Rack and pinion MacPherson strut 78 mm 3 07 in Unit Swing 78 7 mm 3 10 in Drum Hydraulic Drum Mechanical internal expansion 12 14 Ah Semi sealed beam 12V35Wx 2 12 V 21 5 W 12V10W Single phase AC 17 12 5 V 420 kg 926 Ib 181 kg 400 Ib 1 12 GENERAL INFORMATION General Specifications Items KAF400AAF ACF CAF KAF400BAF Dimensions Overall Length Overall Width Overall Height Wheelbase Tread Front Rear Ground Clearance Seat Height Curb Weight Front Rear Fuel Tank Capacity Cargo Bed L x W x H Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System
44. C Parking Brake Lever Mounting Bolts D Frame Ground Terminal E Parking Brake Lever Assembly F Parking Brake Lever Installation e Install Parking Brake Lever Assembly Frame Ground Terminal A Parking Brake Lever Mounting Bolts e Tighten Torque Parking Brake Lever Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Install Parking Brake Light Switch Lead Connector B Parking Brake Cable and Adjusting Nuts C 12 22 BRAKES Parking Brake Lever and Cables xIf the adjusting nut doesn t reach the cable loosen the adjuster mounting nuts A e Adjust the parking brake lever see Parking Brake Lever Inspection in the Periodic Maintenance chapter e Install Rubber Cover A OJust push the hole of the rubber cover onto the battery holder rod B Battery C NOTE ODo not tighten the cover with the rod nut D OPut the rubber cover on the parking brake lever assembly E through the slit of the cover e Install Bracket F Washers G Bracket Bolts H e Tighten the band A through the upper and lower holes B of the rubber cover and over the cable bracket B e Install Left Side Cover see Frame chapter 1 09000851 C SUSPENSION 13 1 Suspension Table of Contents Exploded WE 13 2 Specifications o mata ee Ib B Witte E 13 4 Special TOs 13 5 Struts and Rear Shock 13 6 Strut Front S
45. C and secondary cups D cup is worn damaged softened rotted or swollen replace it x If fluid leakage is noted at the brake push rod the sec ondary cup of the primary piston should be replaced e Check the dust cover E for damage x If it is damaged replace it e Check that the relief F and supply G ports are not plugged xIf the small relief port becomes plugged the brake shoes will drag on the drum Blow the ports clean with com pressed air e Check the piston return springs H for any damage x If the spring is damaged replace it 1M05000BS2 C 12 12 BRAKES Brake Hoses and Pipes Brake Hose and Pipe Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Hose and Pipe Replacement e Refer to the Brakes in the Periodic Maintenance chapter BRAKES 12 13 Brake Drums Brake Drum Removal e Remove Wheel see Wheels Tires chapter Cotter Pin A Axle Nut B and Washer OLoosen the axle nut while applying the brake and release the brake OYou can also loosen the axle nut using the brake drum holder special tool Special Tool Brake Drum Holder 5700 1325 e Be sure to release the parking brake when removing the rear brake drum e The brake drums are press fitted on the axles Use the brake drum remover set and rotor puller special tools to remove the drums OMount the brake drum remover on the drum studs with the remover nuts and washers parts in t
46. Circlip Pliers Steering Stem Nut Wrench 57001 144 57001 1100 7570144ST C 875711005 C 13 6 SUSPENSION Struts and Rear Shock Absorbers Strut Front Shock Absorber Removal e Remove Front Cargo Compartment see Frame chapter Front Wheel see Wheels Tires chapter Brake Panel Assembly see Brakes chapter Tie rod End A see Knuckle Removal in the Steering chapter e Remove Cotter Pin A Strut Clamp Bolt and Nut B e Remove Suspension Arm Bolts A Suspension Arm with Steering Knuckle B e Remove Strut Mounting Nuts A Strut Strut Front Shock Absorber Installation e Insert the strut into the steering knuckle A while aligning the notch B on the strut with the clamp bolt hole C on the steering knuckle e Tighten Torque Strut Mounting Nuts 49 N m 5 0 kgf m 36 ft Ib Strut Clamp Nut 98 N m 10 kgf m 72 ft lb SUSPENSION 13 7 Struts and Rear Shock Absorbers e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the bolt tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slit goes past the nearest hole 1407000851 e Bend the cotter pin A over the nut e Install the removed parts see appropriate chapter Rear Shock Absorber Preload Adjustment The spring adjusting sleeve A on the rear shock ab
47. Clamp Nuts Tie rod End Nuts Frame Fastener Remarks Parking Brake Lever Mounting Bolts 25 2 5 18 Bleed Valves 7 8 0 80 69 in lb Wheel Cylinder Mounting Bolts 12 1 2 106 in Ib Breather Fitting KAF400 A C 6 0 0 61 53 in lb Front Brake Panel Mounting Bolts 34 3 5 25 L Front Axle Nuts 147 15 108 Brake Pipe Mounting Bolt 25 2 5 18 Rear Brake Panel Mounting Bolts 34 3 5 25 L Rear Axle Nuts 304 31 224 Suspension Strut Mounting Nuts 44 4 5 32 Strut Clamp Nuts 98 10 72 Front Suspension Arm Pivot Bolts 88 9 0 65 Front Suspension Arm Joint Nuts 78 8 0 58 Swingarm Joint Nut 54 5 5 40 Swingarm Rod Bolts 50 5 1 37 Rear Shock Absorber Mounting Nuts 54 5 5 40 Front Bar Mounting Bolts Lower 98 10 72 Front Bar Mounting Bolts Upper 44 4 5 32 Rear Bar Mounting Bolts L 20 mm 44 4 5 32 Rear Bar Mounting Bolts L 16 mm 44 4 5 32 Seat Belt Mounting Bolts 34 3 5 25 Electrical System Fan Housing Bolts 5 9 0 60 52 mb Alternator Rotor Bolt 56 5 7 41 Ignition Coil Bolts 5 9 0 60 52 in lb Spark Plug 22 2 2 16 Stator Coil Screws 3 4 0 35 30 in lb Wire Lead Clamp Bolt 6 9 0 70 61 Starter Motor Mounting Bolts 17 1 7 12 Starter Motor Terminal Nut 8 8 0 90 78 mb Controller Mounting Bolt KAF400 A C 5 4 0 55 48 in lb Regulator Rectifier Bolts 7 8 0 80 69 in Ib 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nm kgf m Remarks Joint KAF400 A C 7 4 0 75 65 in lb Oil Temperatur
48. E lightly by hand e Install the engine ground lead KAF400 A1 AAF B1 BAF C1 CAF Models Install the engine ground lead KAF400ABF ACF BBF BCF Models e Install the connecting plate H to the engine and trans mission case so that the plate fits to the face shown by spigot joint areas I e Apply a non permanent locking agent Connecting Plate Bolts M10 J Connecting Plate Bolts M8 K e Install the washers and tighten the connecting plate bolts M10 and 8 lightly by hand e Install the assembly jig L and tighten the bolts Special Tool Assembly Jig 57001 1631 e Tighten the bolts in the following order Torque Connecting Plate Bolts M10 55 N m 5 6 kgf m 41 ft lb Connecting Plate Bolts M8 28 N m 2 9 kgf m 21 ft Ib Engine Mounting Bolts and Nuts 40 N m 4 1 kgf m 30 16 e Remove the assembly jig When the installing of the assembly jig is not complete retry from beginning OThe above is one of methods If itis a method of adjusting alignment using the assembly jig special tool it is allow able the another method ENGINE REMOVAL INSTALLATION 7 7 Engine Removal Installation AA SI A 7 E E 1194004844 C ENGINE BOTTOM END 8 1 Engine Bottom End Table of Contents Exploded WE 8 2 Specifications s o Ota eI Rte mnt RR 8 4 ejerce 8 6
49. Front Cargo Compartment Installation 15 19 Cargo Bed DS 15 20 Cargo BEd enne E EE 15 20 Cargo Bed Assembly 15 21 tte e e Te ER tee RE ERE 15 21 Cargo Bed Latch Position enne 15 22 Cargo Bed Latch Position Adjustment Ne 15 23 Front Bar Removab TECNICI Front Bar InstallatiOni EE Rear Bar Retnoval x e e e ee dug Rear Bar Installation sorte eee Pea UE A ioe st td EE i MUT Front Fender Installation pp EI Ee RE lut Re TEE Front Guard Rernoval A ei cn ade lates Front Guard Installati n og per eR YR ERR Floor Center Panel x rtt EE Floor Center Panel Installation Front Final Gear Case Guard Removal nennen 15 27 Front Final Gear Case Guard Installation pp 15 27 Bottom Guard Removal nnene nenne 15 27 Bottom Guard Installation Nt 15 28 Transmission Case Guard Removal eene 15 28 Transmission Case Guard Installation nnn 15 28 Center Cover Removal 4 15 28 Center Cover EE EE EE 15 28 Side Covers Remova e eere ert RR RR e Rx 15 29 Side Govers InstallatiOn s t coe et deo ine
50. Front and Rear Bar Mounting Bolts and Nuts Front Guard Mounting Nuts Cargo Bed Hook Mounting Bolts Cargo Bed Mounting Pin Clips Screen Mounting Nuts Seat Bracket Nuts and Bolts Seat Back Mounting Nuts Seat Belt Mounting Bolts Battery Holder Nuts FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded View Specifications Throttle Pedal and Throttle Pedal Free Play Inspection pp Throttle Pedal Free Play e EE EE Full Throttle Pedal Position Adj stmeht ees Throttle Cable Installation Throttle Cable Lubrication Throttle Cable Inspection Governor Link Control Panel Assembly Removal Control Panel Assembly Installation Governor Assembly Removal Governor Assembly Installation Governor Assembly Inspection Choke Choke Knob Free Play Inspection Choke Knob Free Play Adjustment Choke Cable Installation Choke Cable Lubrication Choke Cable Inspection Carburetor Idle Speed Inspection Idle Speed Adjustment Fuel System Cleanliness Carburetor Remowval Carburetor Installation
51. Inspection e Check the needle bearing OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Visually inspect the oil seal Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged 6J06002BS1 C TRANSMISSION 9 39 Transmission Sectional Figure KAF400 A C 9 40 TRANSMISSION Transmission Sectional Figure KAF400 A C except Europe Model KAF400 A C Europe Model TRANSMISSION 9 41 Transmission Sectional Figure 400 9 42 TRANSMISSION Transmission Sectional Figure KAF400 B except Europe Model KAF400 B Europe Model WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded 10 2 leede m EE 10 4 teya o Kate uL 10 5 ul EE 10 6 en EE 10 6 De nei ead ede be ae ea 10 7 Wheel ne CEET 10 7 Wheel Installation enema 10 7 Wine Rim TAS PS CUO Rs on Eb te abet Rut eaa ans acu potu 10 7 Wheel Rim Replacement pp 10 8 HIE 10 9 HU Cu CIE 10 9
52. Installation OWhen install the rubber bushings A in the swingarm rod B lubricate them with a soap and water solution Do not use engine oil or petroleum distillates to lu bricate the bushings because they will deteriorate the rubber 1NO8000BS1 C 13 12 SUSPENSION Swingarm e Replace the swingarm rod nuts with new ones e Clean the sealing surface and the taper surface A of the frame bracket and shank B of the swingarm joint or the tapers will not fit snugly e Install Swingarm Joint Nut and Washer Swingarm Rod Bolt and Nut e Tighten Torque Swingarm Joint Nut 54 N m 5 5 kgf m 40 ft Ib Swingarm Rod Bolt 50 N m 5 1 kgf m 37 ft lb e Install Bolt and Connecting Wire Swingarm Inspection e Visually inspect the swingarm for breaks or distortion x If the swingarm is damaged any way replace it e Visually inspect the rubber bushings A in the swingarm rod B x If they are worn cracked hardened or otherwise dam aged replace them with new ones Swingarm Joint Replacement e Remove Swingarm see Swingarm Removal Circlip A Special Tool Outside Circlip Pliers B 57001 144 OUsing a press remove the swingarm joint C e Replace Swingarm Joint Circlip e Using a press install the swingarm joint e Install Circlip Special Tool Outside Circlip Pliers 57001 144 1408001851 C 1NO8000BS1 C STEERING 14 1 Steering Table of Contents
53. Installation e Install O rings A Collars B and Dampers C 17048024 e For KAF400AAF BAF CAF Later Models Apply liquid gasket D to the mating surface of the collars B Sealant Liquid Gasket TB1215 92104 1065 e Install Torque Converter Case Converter Case Front Bolts 26 5 mm 1 04 in E O rings F Washers G Converter Case Rear Bolts 25 mm 0 98 in H Converter Case Cover I Screws J e Set the trim seal juncture in this area L when inserting the trim seal M in the torque converter case N L 40 mm 1 57 in e Tighten Torque Converter Case Front Bolts 20 N m 2 0 kgf m 15 ft Ib Converter Case Rear Bolts 20 N m 2 0 15 ft Ib Converter Case Cover Screws 5 0 N m 0 51 kgf m 44 in Ib e Install Cable Holder Bolts e Tighten Torque Cable Holder Bolts 8 8 0 90 kgf m 78 in Ib 5 16 CONVERTER SYSTEM Torque Converter Drive Belt CONVERTER SYSTEM 5 17 Drive Belt Removal e Refer to the Torque Converter Removal Drive Belt Installation e Refer to the Torque Converter Installation Drive Belt Inspection e Refer to the Converter System in the Periodic Mainte nance chapter Drive Belt Deflection Inspection e Refer to the Converter System in the Periodic Mainte nance chapter Drive Belt Deflection Adjustment e Refer to the Converter System in the Periodic Mainte nance chapter 5 18 CONVERTER SYSTEM Drive
54. KAF400ABF 55 0 56 48 in lb 2 Carburetor Mounting Nuts 6 9 0 70 61 in Ib 3 Choke Valve Screws 0 90 0 09 7 8 in lb L 4 Throttle Valve Screws 0 90 0 09 7 8 in lb L 5 Pilot Jet 0 70 0 07 6 1 in Ib 6 Pilot Jet Plug 2 5 0 25 22 in lb 7 Main Jet 2 0 0 20 17 in lb 8 Drain Screw 2 0 0 20 17 in lb 9 Float Chamber Bolt 9 8 1 0 87 10 Pilot Screw 11 Idle Adjustung Screw 12 Choke Cable 13 Throttle Cable G Apply grease L Apply a non permanent locking agent R Replacement Parts 3 4 FUEL SYSTEM Exploded View SC S FUEL SYSTEM 3 5 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Panel Cover Bolts 4 4 0 45 39 in Ib 2 Control Panel Bolt 8 8 0 90 78 mb 3 Plate Connection Bolts 8 8 0 90 78 in lb 4 Control Panel Mounting Bolts 20 2 0 14 5 Governor Arm Nut 7 4 0 75 65 in Ib 6 Fuel Pump Mounting Bolts 5 4 0 55 48 in Ib Cleaner Housing Bolts 17 1 7 12 7 i i 3 Ge Bolts KAF400ABF 55 0 56 48 in lb 8 Fuel Pump Bracket Bolt 5 4 0 55 48 in lb 9 Breather Mounting Bolt 8 8 0 90 78 in lb 10 Breather Bracket Bolt 15 1 5 11 11 Breather Hose Clamp Mounting Bolt 5 5 0 56 48 in lb 12 Canister Bracket Bolt L 18 5 4 0 55 48 in lb 13 Canister Bracket Bolts L 12 8 8 0 90 78 in lb 14 Canister Bracket Bolts L 20 19 6 2 0 14 15 Governor 16 Fuel Pump 17 Fuel Filter 18 Canister 19 Fu
55. Pulley Drive Pulley Removal e Refer to the Torque Converter Removal Drive Pulley Disassembly e Remove Drive Pulley see Torque Converter Removal e Hold the drive pulley holder A in a vise Special Tool Drive Pulley Holder 57001 1628 e Set the pulley onto the pulley holder e Remove Drive Pulley Cover Bolts A Drive Pulley Cover B e Remove Spring A Spacer e Put the drive pulley wrench A on the spider B Special Tool Drive Pulley Wrench 57001 1627 e Turn the wrench counterclockwise and remove the spider with the movable sheave CONVERTER SYSTEM 5 19 Drive Pulley e Remove Spider A Shoes B Nuts C Ramp Weight Pin D Ramp Weight E Movable Sheave F Fixed Sheave G IF06018BS2 C Drive Pulley Inspection x If the sheave surfaces A appear damaged replace the sheaves e Replace any sheave which has uneven wear on the belt contacting surface Straight Edge B x If the cover bushing is damaged or worn replace the drive pulley cover Cover Bushing Inside Diameter A Standard 28 005 28 089 mm 1 103 1 106 in Service Limit 28 3 mm 1 114 in x If the sheave bushing is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 35 002 35 087 mm 1 378 1 381 in Service Limit 35 3 mm 1 390 in 5 20 CONVERTER SYSTEM Drive Pulley x If the spider shoes A are damaged replace them e Check the spider shoe side
56. Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the intake manifold Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a catalytic converter in the muffler California model a modified carburetor and ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps main tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere 3 1 Evaporative Emission Control System Europe model The evaporative emission control system for this utility vehicle consists of low permeation fuel hoses 3 2 Evaporative Emission Control System US and Canada models The evaporative emission control system for this utility vehicle consists of low permeation fuel hoses and fuel tank Also vapors caused by fuel evaporation i
57. Set is used the position will be secured e Apply rubber lubricant oil to inside area of the new grease seal e Put the brake panel A on the flat plate B so that the cable bracket bolt C is not contact to the plate e Put the guide D in the panel Special Tool Grease Seal Driver Set 57001 1629 e Put the grease seal E on the brake panel evenly e Put the grease seal driver A on the grease seal evenly Special Tool Grease Seal Driver Set 57001 1629 e Putthe compressor B to center on the grease seal driver Special Tool Clutch Spring Compressor 57001 1162 e Using a press install the grease seal e Apply lithium grease Grade No 2 to the grease seal lips see Brake Drum Installation e Tighten Torque Bleed Valve 8 0 0 82 kgf m 71 in Ib Breather Fitting 6 0 N m 0 61 kgf m 53 in Ib 1M08005BS1 C BRAKES 12 21 Parking Brake Lever and Cables Parking Brake Lever Travel Adjustment e Refer to the Brakes in the Periodic Maintenance chapter Parking Brake Cable Lubrication Inspection e Refer to the General Lubrication in the Periodic Mainte nance chapter Parking Brake Lever Removal e Remove Left Side Cover see Frame chapter Bracket Bolts A washers and Bracket B Band C e Unhook the rubber cover A from the battery holder rod B and remove it e Remove Parking Brake Light Switch Lead Connector A Adjusting Nuts B and Parking Brake Cable
58. a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows 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 spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents BGIORS puel T le el Bien Te e c x c e eee eer e ce oe eee aee e ec er e eer e ge e ee Model IdentfiCaliOris ss ree ee mes E E ENEE General Specifications mi i ee orte reete d e a rrr rt rid roe eee lis e dieto 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper ation on a vehicle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the vehicle disconnect the battery cables from the battery to prevent the engine 2 So from acciden
59. and Master Cylinder epe tdt n e trea EES 12 10 Brake Pedal Play Inspection s un ee tee te Lec ere eee tug 12 10 Master Cylinder e EE 12 10 Master Cylinder Installation oo e tot t SEL Eege 12 10 Master Cylinder Disassembly Assembly 12 10 Master Cylinder Inspector oa odore te pea Macatee Ee order ten de aude edades 12 11 Brake Hoses and PIpess i PC er ta v e o E RE Ct gn 12 12 Brake Hose and Pipe Inspection 4 12 12 Brake Hose and Pipe 12 12 Brake eerste Brake Drum Removal Brake Drum Installatiom eoe Brake Drum iore ti setate Resp A RE nat ob tan Brake Panel Assemblies nenia aaa iE A EAA Brake Panel Assy Removal uo oeio d t ie pad E Brake Panel Assy Installation Brake Panel Disassembly eat Gode Brake Panel Assembly EE Wheel Cylinder Removal Installation 4 12 19 Wheel Cylinder Assembly 12 19 Wheel Cylinder Inspection 4 12 19 Brake Shoe Lining sione oret ep s det 12 19 Brake Shoe Spring Inspection pp 12 20 Grease Seal Replacement 400 2 21 2 10 nennen nentes 12 20 Parking Brake Lever and Cables Ne 12 21
60. as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact 11 14 FINAL DRIVE Front Final Gear Case KAF400 A C e Assemble the gear case temporarily for the gear backlash adjustment OClean the mating surface of the front final gear case and cover Olnstall Pinion Gear Unit A Shim B Ring Gear Assembly C Olnstall Shim A e Apply a non permanent locking agent Ring Gear Cover Bolts M10 A OTighten Torque Ring Gear Cover Bolts M10 47 N m 4 8 kgf m 35 ft Ib Ring Gear Cover Bolts M8 25 N m 2 5 kgf m 18 ft Ib OTighten Torque Pinion Gear Bearing Holder A 98 N m 10 kgf m 72 ft lb Special Tool Socket Wrench Hex 48 57001 1401 OAdjust the gear backlash and tooth contact pattern see Front Final Bevel Gear Adjustment OSplit the front final gear case see Front Final Gear Case Disassembly FINAL DRIVE 11 15 Front Final Gear Case KAF400 A C e Clean the mating surface of the front final gear case and cover e Apply liquid gasket to mating surface A and flange B of the gear case cover Sealant Liquid Gasket TB1216B 92104 1063 e Apply a non permanent locking agent Ring Gear Cover Bolts M10 A e Tighten Torque Ring Gear Cover Bolts M10 47 N m 4 8 kgf m 35 ft lb Ring Gear Cover Bolts M8 25 N m 2 5 kgf m 18 ft lb e Stake A the pinion gear bearing holder B with a pun
61. care the direction e Apply molybdenum disulfide grease to the threads and seating surface of new drive bevel gear nut D e Face caulking side E to outward e Tighten Special Tool Bevel Gear Holder 57001 1638 Torque Drive Bevel Gear Nut 137 N m 14 kgf m 101 ft Ib Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load the backlash of the bevel gears must be correct to prevent the gears from making noise and being damaged When replacing any one of the backlash related parts be sure to check and adjust the backlash Adjust the backlash by replacing shims This adjustment is of critical importance and must be carried out in the correct sequence using the procedures shown 1LO5009BS2 C 11 32 FINAL DRIVE Bevel Gear Case KAF400 A C Backlash Adjustment e Check and adjust the gear backlash when any of the backlash related parts are replaced with new ones e Install Bevel Gear Holder A see Drive Bevel Gear Removal Special Tool Bevel Gear Holder 57001 1638 e Clean any dirt and oil off the bevel gear teeth e Install Drive Bevel Gear see Drive Bevel Gear Installation Driven Bevel Gear see Driven Bevel Gear Installation Bevel Gear Holder B Special Tool Bevel Gear Holder 57001 1639 e Tighten Torque Bevel Gear Case Bolts 20 N m 2 0 kgf m 14 ft Ib e Set up a dial gauge C against one of the teeth in the bevel gear D e To measure th
62. distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum e Adjust Parking Brake Lever Inspection see Parking Brake Lever Inspection in the Periodic Maintenance chapter Brake Panel Disassembly e Remove Brake Drum see Brake Drum Removal Brake Pipe Nipple A and Brake Pipe B If the brake panel or wheel cylinder are removed e Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 1408002851 C 12 16 BRAKES Brake Panel Assemblies e Using a suitable tool remove the brake shoe spring A e While pushing the shoe hold down spring A turn the pin B 90 and remove the spring e Remove Shoe A Shoe Spring B Parking Brake Lever Linkage C NOTE OWrap the brake shoes with a clean cloth to protect the linings from grease or dirt e While pushing the shoe hold down spring A turn the pin B 90 and remove the spring e Remove Shoe C e Remove for Rear Brake Panel Parking Brake Cable End s OHold the bolt A and loosen the nut Do not turn the bolt The bolt is engaged by the spline in the brake panel When removing the cable loosen the nut only ORemove Parking Brake Cable Bracket B Parking Brake Cable BRAKES 12 1
63. e Check battery condition see Charging Condition Inspec tion in the Periodic Maintenance chapter NOTE OAlways check battery condition before condemning other parts of the charging system The battery must be fully charged in order to conduct accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulator rectifier output voltage at various en gine speeds with the headlights turned on and then turned off OConnect a voltmeter across the battery terminals e The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must stay within the specified range x If the output voltage is much higher than the specification the regulator rectifier is defective or the regulator rectifier leads are loose or open xIf the output voltage does not rise as the engine speed increase then the regulator rectifier is defective or the al ternator output is insufficient for the loads Regulator Rectifier Output Voltage Standard Battery Voltage 15 V 16 26 ELECTRICAL SYSTEM Charging System Stator Coil Resistance e Disconnect the alternator leads connector e Measure the stator coil resistance OConnect an ohmmeter between the alternator leads Stator Coil Resistance Standard 0 3 or less x If the meter does not read as specified replace the alter nator stator
64. e Measure the width A of the belt at several locations with a pair of suitable straightedges B as shown x If any measurements exceed the service limit replace the belt Belt Width Standard 26 1 27 3 mm 1 03 1 07 in Service Limit 25 2 mm 0 99 in IF08000BS1 Detail X Section Y Y 7 2 Ore zeg AEN CA 1 080028 2 HUO8002BS1 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the belt for wear cracks breaks or peeling If necessary replace the belt with a new one Belt A Crack B Broken C NOTE OWhenever the belt is replaced inspect the drive and the driven pulleys Converter Drive Belt Deflection Inspection e Remove the torque converter cover see Converter Sys tem chapter e Putthe transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley e Measure the belt deflection A at the three locations by rotating the pulley as shown OPlace a straightedge B on top of the belt between the drive pulley C and the driven pulley D OUse a ruler to push the belt away from the straightedge Push hard but with no more force than 59 N 6 kgf 13 Ib Belt Deflection Standard 22 32 mm 0 87 1 26 in Service Limit 22 44 0 87 1 73 x If the belt deflection of all of the three locations is within the speci
65. ignition coil and the magnet to the specified gap value as shown Ignition Coil Air Gap Standard 0 2 0 4 mm 0 0079 0 0157 in e Tighten the ignition coil bolts following the tightening se quence 1 2 Torque Ignition Coil Bolts 5 9 0 60 kgf m 52 in Ib NOTE OAbove procedure must be used to insure proper coil air gap is not too large KH0O8013BS1 C Ignition Coil inspection e Remove the ignition coil see Ignition Coil Removal e Measure the winding resistance as follows OSet the hand tester to the R x 1 kO range Special Tool Hand Tester 57001 1394 OMake the measure shown in the table Ignition Coil Winding Resistance B gem P 2 18 kQ C 2 18 10 30 kO NOTICE Use only Tester 57001 1394 with new battery at room temperature for this test A tester other than the Kawasaki Hand Tester may show different read ings If a meter with a large capacity battery is used the ignition coil will be damaged x If the tester does not read as specified replace the coil 16 32 ELECTRICAL SYSTEM Ignition System Ignition System Circuit oFF ON W BK BK BK 24 BK BK Y BK Y 1010002882 C 1 Ignition Switch 2 Ignition Coil 3 Spark Plug 4 Alternator Rotor ELECTRICAL SYSTEM 16 33 Electric Starter System Starter Motor Removal e Remove Torque Converter Case see Converter System chapter Connecting Plate Bolts A Conn
66. includes any appliance with a pilot light NOTICE If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e Connect the hoses according to the diagram of the sys tem Make sure they do not get pinched or kinked Hose Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Canister Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter 3 30 FUEL SYSTEM Evaporative Emission Control System California Model KAF400ABF ACF BBF BCF US and Canada Models 1Ci4003BW3 C Fuel Tank Air Cleaner Duct Band for Canister Canister Fuel Filter Fuel Hose Canister Fuel Filter Fuel Hose Canister Air Cleaner Duct Fuel Hose Fuel Tank Canister Fuel Hose Check Valve KAF400A9F ACF B9F BCF C9F CAF Models Log ion ENGINE TOP END 4 1 Engine Top End Table of Contents 2 4 2 EXAAUSE OY StI 4 4 4 5 eet EEN 4
67. not be obstructed 1505005851 C PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked when the engine is cold at room temperature e Remove Guard Plates see Frame chapter Cooling Fan Cover see Alternator Rotor and Stator Re moval section in the Electrical System chapter Oil Level Gauge A Cylinder Head Cover Bolts B Cylinder Head Cover C Spark Plugs e Position the crankshaft at TDC of the end of the compres sion stroke e Turn the alternator rotor counterclockwise so that the pro jection A on the plate B comes to the cylinder as shown ORemove the spark plug if the thin rod is inserted in the plug hole and the rotor is rotated a top position of the piston is understood e Check both rocker arms are free If not turn the rotor more one turn and free both rocker arms e Using a thickness gauge A measure the valve clearance between the rocker arm and the valve stem x If the valve clearance is incorrect adjust it Valve Clearance when cold Standard 0 10 0 15 mm 0 0039 0 0059 in Valve Clearance Adjustment e Loosen the valve adjusting nut lock screw A e Turn the valve adjusting nut B until the correct clearance is obtained e Holding the adjusting nut tighten the lock screw Torque Valve Adjusting Nut Lock Screw 6 9 N m 0 70 kgf m 61 in Ib 2 18 PERIODIC MAINTENANCE
68. removed e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs in the same manner GE16060881 C 8 12 ENGINE BOTTOM END Cylinders and Pistons Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way e Do not mix up the top and second rings e Install the second ring so that the notched edge A faces down e Install the top ring e The rings should turn freely in the grooves Piston Head B Top Ring C Second Ring D e Align the piston and rings with the piston ring end gap as shown Arrow Match Marks A Top ring End Gap Upper Steel Rail End Gap B About 45 C Second Ring End Gap Lower Steel Rail End Gap D e Apply engine oil to the piston pins e Assemble the piston onto the connecting rod so that the arrow mark A on the top of the piston can be aligned with MADE B on the connecting rod e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole OWhen installing a piston pin snap ring compress it only enough to install it and no more NOTICE Do not reuse th
69. screw B on the control panel and idle adjusting screw C on the link bracket e Turn the idle adjusting screw A at the carburetor until the idle speed is correct Idle Speed Standard 1 100 1 250 r min rpm e After the adjustment screw in the idle adjusting screw A on the link bracket until the screw lightly touches the link lever B e Finally screw in the accel lever stopper screw C until it keeps clearance by 1 mm 0 04 in to accel lever D e Depress and release the throttle pedal a few times to make sure that the idle speed does not change Read just if necessary Fuel System Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Cargo Bed tilt up e Place a suitable container under the carburetor e Turn out the drain screw A a few turns to drain some fuel from the carburetor and check for water or dirt in the fuel any water or dirt comes out clean the carburetor and fuel tank see Fuel Tank and check the fuel filter e Tighten the drain screw securely PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE dusty areas the element should be cleaned more frequently than the recomm
70. see Steering chapter Steering Gear Assembly Mounting Rubber Dampers Tie rod End Nuts see Wheels Tires chapter Steering Gear Preload Adjustment see Steering chap ter x If the inspections above are good but the free play is out of the specified the steering gear assembly is damaged and should be replaced as a unit 1004000851 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Steering Joint Dust Boot Inspection e Visually inspect the dust boots A at both the ends of the steering gear assembly x If there is any signs of deterioration cracks or damage replace the steering gear assembly together with these boots Frame Seat Belt Inspection e Check the belt A for damage or tear x If necessary replace the belt with a new one e Check the tightness torque of the seat belt mounting bolts B Torque Seat Belt Mounting Bolts 34 3 5 kgf m 25 ft Ib e Check the operation of the buckle A OSet the plate B in the buckle and confirm the plate does not come off when pulling it OSet the plate in the buckle and confirm the plate comes off when the buckle button C is pushed x If operation is not correct visually inspect the plate xIf the plate is damaged replace the plate assembly with a new one x If the plate is not damaged replace the buckle assembly Electrical System Battery Inspection Electrolyte Level e The electrolyte level should be between the upp
71. shaft if necessary e Check the top of the cam lobes B for wear burrs or un even contact Replace the shaft if necessary e Inspect the camshaft to make sure that its Automatic Compression Release ACR function operates smoothly and does not have any damage or abnormal wear If ACR parts are worn replace the camshaft x When the weight A is closed if the top of the shaft B is lower than the base C replace the camshaft with a new one x When the weight is pulled entirely outward with your fin ger if the top of the shaft is higher than the cam base replace the camshaft with a new one KG05010BS1 C KG05015BS1 C 8 10 ENGINE BOTTOM END Camshaft and Tappets Camshaft Bearing Journal Wear e Measure the height of each cam lobe A If the cam height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Standard Inlet 29 955 30 045 mm 1 179 1 183 in Exhaust 29 955 30 045 mm 1 179 1 183 in Service Limit Inlet 29 86 mm 1 176 in Exhaust 29 86 mm 1 176 in e Measure both camshaft journals at several points around the journal circumference xIf the journal diameter is less than the service limit re place the camshaft Crankcase Side Camshaft Journal Diameter Standard 19 967 19 980 mm 0 7861 0 7866 in Service Limit 19 94 mm 0 785 in Crankcase Cover Side Camshaft Journal Diameter Standard 49 959 49 9
72. so that the engine oil be tween the piston and the cylinder wall will help seal com pression as it does during normal running e Stop the engine remove the spark plug and attach a compression gauge A firmly into the spark plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M14 x 1 25 B 57001 1159 e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising this is the highest compression reading obtainable Cylinder Compression Usable Range 340 590 kPa 3 5 6 0 kgf cm 50 85 psi 530 r min rpm e Repeat the measurement to the other cylinder The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and Remove the carbon deposits and compression cylinder head and in combustion replace damaged parts if necessary higher than usable chamber possibly due to damaged range valve stem oil seal and or damaged piston oil rings Incorrect cylinder head gasket Replace with a gasket of the proper thickness thickness Cylinder Gas leakage around cylinder head Replace damaged gasket and check compression lower cylinder head warp than usable range Bad condition of valve seating Repair if possible Incorrect valve piston cylinder Adjust clearance Piston seizure Inspect cylinder and liner a
73. surface A between the valve B and valve seat C e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around NOTE OThe valve stem and guide must be in good condition or this check will not be valid x If the valve seating pattern is not correct repair the seat e Measure the outside diameter D of the seating pattern on the valve seat x If the outside diameter of the valve seating pattern is too large or too small repair the seat Valve Seating Surface Outside Diameter Inlet 32 8 mm 1 291 in Exhaust 27 6 mm 1 087 in e Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Too Wide G Too Narrow H Uneven J If the width is too wide too narrow or uneven repair the seat See Valve Seat Repair Valve Seating Surface Width Standard Inlet 1 1 1 7 0 043 0 070 in Exhaust 1 0 1 5 mm 0 039 0 059 in 8 15011752 C Valves ENGINE TOP END 4 13 Valve Seat Repair e Follow the manufacturer s instructions for use of valve seat cutters Special Tools Valve Seat Cutter 45 535 57001 1116 IN Valve Seat Cutter 32 538 5 57001 1122 IN Valve Seat Cutter 45
74. the bearing driver set Special Tool Bearing Driver Set 57001 1129 Knuckle Bearing Installation e Press in the bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 Knuckle Joint Removal e Remove Steering Knuckle see Steering Knuckle Removal Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove the knuckle joint A using a press Special Tool Knuckle Joint Remover B 57001 1619 14 12 STEERING Steering Knuckles Knuckle Joint Installation e Press the knuckle joint A until it is bottomed Special Tool Knuckle Joint Driver B 57001 1640 e Replace the circlip with a new one Special Tool Outside Circlip Pliers 57001 144 FRAME 15 1 Frame Table of Contents Exploded i i 15 2 ee Elle Ee TEE 15 14 oeat Removals te Ee 15 14 ES 15 14 Seat Belt Removal ctc 15 15 Seat Belt Installato neede heen ess dag ae deett Age 15 15 Control Pane linia ase tease 15 16 Gontrol Paneli Removals itr oot temet t adio cis ace ae 15 16 Glove Compartment Removal entren nnne nnns 15 17 Front Cargo nnne nne 15 18 Front Cargo Hood Removal 15 18 Front Cargo Compartment Removal 15 18
75. the seat with machinist s dye e Fit a 45 cutter to the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced e Measure the outside diameter O D of the seating sur face with a vernier caliper x If the O D of the seating surface is too small repeat the 45 grind until the diameter is within the specified range xIf the O D of the seating surface is too large make the 32 grind described below e Grind the seat at a 32 angle until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter to the holder and slide it into the valve guide the holder one turn at a time while pressing down very lightly Check the seat after each turn The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat O D mea surement step above e Lap the valve to the seat once the seat width and O D are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSp
76. this includes any mE appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes and broken wire x If the screen is damaged replace it 6 12 ENGINE LUBRICATION SYSTEM Oil Temperature Sensor KAF400 A C Oil Temperature Sensor Removal e Remove Engine oil drain see Engine Oil Change in the Periodic Maintenance chapter Sensor Lead Connector Oil Temperature Sensor A Oil Temperature Sensor Installation e Apply engine oil to the O ring on the sensor e Tighten Torque Temperature Sensor 5 4 0 55 kgf m 48 in Ib Joint B 7 4 N m 0 75 kgf m 65 in Ib 1G06000BS1 C ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents e ollo 1o Ee lA Eo TE 7 2 Special Toob E 7 4 EE te EE 7 5 Engine FREMOW AL 7 5 en e OM 7 6 7 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 7 3 Exploded View Engine Mounting Bots and Nus 40 441 R 4 KAF400ABF ACF BBF Models L Apply a non permanent locking agent R Replacement Parts 7 4 ENGINE REMOVAL INSTALLATIO
77. yi 6 A ELECTRICAL SYSTEM 16 5 Exploded View Torque No Fast Remarks 2 TUNE Nm kgfm ftlb Controller Mounting Bolt KAF AOO AC 5 4 0 55 48 in lb Regulator rectifier Bolts 7 8 0 80 69 in Ib Joint KAF400 A C 7 4 0 75 65 in lb Oil Temperature Sensor KAF400 A C 5 4 0 55 48 in Ib Neutral Switch Reverse Switch EUR 15 1 5 11 2 3 4 5 6 Hour Meter 7 Starter Circuit Relay Brake KAF400 A1 AAF B1 BAF C1 CAF Models 8 Starter Circuit Relay Neutral KAF400 A1 AAF B1 BAF C1 CAF Models 9 Starter Circuit Relay Brake ACF BBF Models 10 Starter Circuit Relay Neutral ACF BBF Models 11 Accessory Connector Power Outlet 12 Light Switch 13 Brake Light Switch 14 Parking Brake Light Switch 15 Horn EUR 16 400 1 A7F B1 B7F C1 Models 17 Other than Australia Model 18 KAF400ABF ACF BBF Models 19 CA KAF400 A1 ABF B1 BBF C1 CAF Models 20 CA KAF400ACF BCF Models G Apply grease R Replacement Parts CA Canada Model EUR Europe Model 16 6 ELECTRICAL SYSTEM Wiring Diagram KAF400 A C eter Accessory H Connector Parking Power Outlet Brake Light Hour e 12V120W Switch Meter S Parking Brake Indicator Light 1291 78 um di x 22 a Accessory Fuse 10A BK Y 7 BK Y BR BR
78. 070 in Exhaust 1 0 1 5 0 039 0 059 in Valve Seat Cutting Angle 45 Valve Spring Free Length 35 mm 1 38 in 32 6 mm 1 28 in Valve Head Thickness 0 7 mm 0 028 in 0 4 mm 0 016 in Valve Stem Bend Less than 0 01 mm 0 0004 in TIR TIR 0 05 mm 0 0020 in Valve Stem Diameter Inlet 6 960 6 975 mm 0 2740 0 2746 in 6 95 mm 0 274 in Exhaust 6 945 6 960 mm 0 2734 0 2740 in 6 93 mm 0 273 in Valve Guide Inside Diameter 7 000 7 015 mm 0 2756 0 2762 in 7 08 mm 0 279 in Valve guide Clearance wobble method Inlet 0 06 0 13 mm 0 0024 0 0051 in 0 29 mm 0 011 in Exhaust 0 10 0 17 mm 0 0039 0 0067 in 0 33 mm 0 013 in 4 6 ENGINE TOP END Special Tools Compression Gauge 20 kgf cm 57001 221 Valve Seat Cutter 45 532 57001 1115 7570221ST C ST571115ST C Valve Seat Cutter 45 535 57001 1116 8 5711165 C Valve Seat Cutter 32 35 57001 1121 S T571121ST C Valve Seat Cutter 32 538 5 57001 1122 875711225 6 Valve Seat Cutter Holder 7 57001 1126 875711255 6 Valve Seat Cutter Holder Bar 57001 1128 875711285 C Compression Gauge Adapter M14 x 1 25 57001 1159 875711595 ENGINE TOP END 4 7 Cylinder Head Cylinder Compression Measurement e Tilt up the cargo bed e Thoroughly warm up the engine
79. 08 3 937 in e Measure connecting rod twist OWith the big end arbor still on the V blocks A hold the connecting rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm 3 937 in length of the arbor to determine the amount of connecting rod twist by using a height gauge B connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit 0 2 100 mm 0 008 3 937 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or dial caliper x If the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Standard 27 4 27 7 mm 1 079 1 091 in Service Limit 27 0 mm 1 063 in e Measure the crankpin width A with a dial caliper x If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Standard 28 0 28 2 mm 1 102 1 110 in Service Limit 28 4 mm 1 112 in KG06016BS1 C KG06017BS1 C KG06018BS1 C ENGINE BOTTOM END 8 19 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Crankpin Wear e Apply a thin film of oil on the thread of the cap bolts e Install the cap bolts and tighten the bolts to the speci fied torque see Piston Installation in the Engine Top End chapter e Me
80. 180 0150 0 8 mm 0 032 in 92180 0151 1 0 mm 0 039 in 92180 0152 1 2 mm 0 047 in 92180 0153 1 4 mm 0 055 in 92180 0154 1 6 mm 0 063 in 92180 0155 1 8 mm 0 071 in 92180 0156 2 0 mm 0 079 in 92180 0157 2 3 mm 0 091 in 92180 0158 2 5 mm 0 098 in 92180 0159 2 8 mm 0 110 in 92180 0160 3 2 mm 0 126 in e Tighten Torque Deflection Bolts 9 0 N m 0 92 kgf m 80 in Ib e With the transmission in neutral rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection e Measure the belt deflection again and repeat the above procedures until it is within the standard range Converter Driven Pulley Shoe Inspection e Remove the driven pulley see Converter System chap ter e Disassemble the driven pulley see Converter System chapter xIf the ramps or the wear shoes B are damaged or worn replace the ramp cap C or the shoes 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Measure the width A between the upper surface B of the movable sheave C and the bottom edge D of worn area of the shoe E xIf the width is greater than the service limit replace the shoe Wear Shoe Width Service Limit 1 9 mm 0 075 in Engine Lubrication System Engine Oil Change e Warm up the engine so that the oil will pick up any sedi ment and drain easily e Place an oil pan beneath the engine e Remove the engine oil drain plug
81. 20088 Inspection Reuse of worn or damaged parts may lead to serious ac i cident Visually inspect removed parts for corrosion discol d oration or other damage Refer to the appropriate sections IN of this manual for service limits on individual parts Replace AN the parts if any damage has been found or if the part is be yond its service limit 68020098 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings Oil seals Grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled 68020108 Assembly Order 2 In most cases assembly order is the reverse of disassem T bly however if assembly order is provided this Service cu Dem i Manual follow the procedures given x e DE gt e SS CH 2 4 68020118 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tighten
82. 3968 in Service Limit 10 16 mm 0 4000 in e Measure the outside A diameter of the pump shaft with a micrometer at several points xIf the diameter is less than the service limit replace the pump shaft Pump Shaft Outside Diameter Standard 12 695 12 715 0 4998 0 5006 in Service Limit 12 645 mm 0 4978 in e Measurer the inside diameter A of the pump shaft bear ing in the crankcase cover with a inside micrometer at several points x the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Standard 12 735 12 750 mm 0 5014 0 5020 in Service Limit 12 811 mm 0 5044 in Relief Valve Removal e Remove Camshaft see Camshaft Tappet Removal in the Engine Bottom End chapter Relief Valve Cover Bolt A Relief Valve Cover B 6 10 ENGINE LUBRICATION SYSTEM Oil Pump Relief Valve Relief Valve Installation e Install Relief Valve Ball A Spring B Relief Valve Cover Relief Valve Cover Bolt Relief Valve Inspection e Visually inspect the relief valve spring steel ball and valve seat in the crankcase any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air AA WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the parts in a we
83. 400 r min rpm 27 9 Nm 2 8 20 6 22 200 r min rpm Carburetor NIKKI 6C1026 Electric starter Magneto and Transistor 20 Constant General Specifications GENERAL INFORMATION 1 13 Items KAF400AAF ACF CAF KAF400BAF Spark Plug Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Grade Viscosity Capacity BPRSES 19 BTDC 61 ABDC 260 58 BBDC 22 ATDC 260 Forced lubrication wet sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE10W 40 1 4 1 5 US qt Drive Train Primary Reduction System Type Reduction ratio Transmission Gear Ratio Forward High Low Reverse Low Final Drive System Type Reduction Ratio Front Rear Overall Drive Ratio Forward High Low Reverse Low Front Final Gear Case Oil A C Type Capacity Belt drive torque converter 3 653 0 794 2 916 35 24 36 18 4 315 41 19 36 18 3 750 30 16 36 18 Gear 2WD Gear 4WD 2WD AAF CAF 3 851 16 18 39 9 ACF 3 852 16 18 x 39 9 4 000 64 16 API GL 5 SAE140 or GL 6 SAE90 Hypoid gear oil for LSD 0 35 L 0 37 US qt 1 14 GENERAL INFORMATION General Specifications Front and Rear Parking brake type Items KAF400AAF ACF CAF KAF400BAF Transmission Oil Type API GL 5 Hy
84. 532 57001 1115 EX Valve Seat Cutter 32 635 57001 1121 EX Valve Seat Cutter Holder 7 57001 1126 Valve Seat Cutter Holder Bar 57001 1128 If the manufacture s instructions are not available use the following procedure Seat Cutter Operating Cares 1 The valve seat cutter is designed only for valve seat re pair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder A in position op erate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE OPrior to grinding apply oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash the cutter with washing oil and apply a thin layer or engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following EE Cutter angle B 91 50 demde Outer diameter of cutter C 8 15011851 C 4 14 ENGINE TOP END Valves Operating Procedures e Clean the seat area carefully e Coat
85. 6 E Ain e Ee 4 7 Cylinder Compression Measurement pp 4 7 n Gylinder Head a Le NEE 4 7 Cylinder Plead InstallatigI 4 8 Push ROC 4 10 Valve Mechanism Remowval Installation 4 10 Rocker Arm Inspection oe aevo e e obe c aen 4 10 Cylinder Head Wal EE 4 11 MAIVOS 4 12 Valve Clearance 4 12 Valve Clearance Adjustment 4 12 Valve Seat 4 12 Valve Seat Repair ec ee tee epe ei ed dete be rel tus i e eger ved e hela ves 4 13 Valve Spring Free Length EE 4 16 Valve Head THICKNESS EE 4 16 ValVe Stem a o AA E 4 16 Valve Stent DIarmieter iait Nien 4 16 Valve Guide Inside Diameter 4 17 Measuring Valve Guide Clearance Wobble 4 17 ExhaustPipe and Muffler t PR ee inane taba 4 18 Exhaust Pipe RemowVal 4 18 len e E EE 4 18 Exhaust Pipe and Muffler Installation pp 4 19 Exhaust Pipe and Muffler 4 19 Spark Arrester ee eicit ente 4 19 4 2 ENGINE TOP END Exploded View KAF400 A C 1E02007885 C ENGINE TOP END 4 3 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Cylinder Head
86. 62 1 3772 in Service Limit 34 93 mm 1 375 in KG06020BS1 C KG06021BS1 C 8 20 ENGINE BOTTOM END Crankshaft and Connecting Rods e Measure the inside diameter A of the crankshaft main bearing crankcase side x If the bearing has worn past the service limit replace the crankcase with a new one Crankshaft Main Bearing Inside Diameter Crankcase Side Standard 35 002 35 015 mm 1 3780 1 3785 in Service Limit 35 05 mm 1 380 in ENGINE BOTTOM END 8 21 Balancer Shaft Balancer Shaft Removal e Remove Crankcase Cover see Crankcase Cover Removal Balancer Shaft A Balancer Shaft Installation e Install the balancer shaft to the balancer shaft bearing on the crankcase e Install the crankcase cover see Crankcase Cover Instal lation e Align the punch marks A on the crankshaft gear and on the balancer shaft gear Balancer Shaft Bearing Journal Wear e Measure both balancer shaft journals diameter A at sev eral points around the journal circumference x If journal diameter is less than the service limit replace the balancer shaft with a new one Balancer Shaft Journal Diameter Standard 31 959 31 975 mm 1 2582 1 2589 in Service Limit 31 935 mm 1 257 in e Measure the inside diameter A of the balancer shaft bearing on the crankcase at several points x If inside diameter is more than the service limit replace the cra
87. 62 in 6 05 6 15 mm 0 2382 0 2421 in 190 50 190 97 mm 7 500 7 518 in 13 95 14 00 mm 0 549 0 551 in 14 0 14 2 mm 0 551 0 559 in 5 8 mm 0 228 in 6 25 mm 0 2462 in 193 4 mm 7 614 in 13 8 mm 0 543 in 14 3 mm 0 563 in Differential Gears and Shift Mechanism Shift Shaft Pin Diameter Shifter Groove Width 8 4 8 6 mm 0 331 0 339 in 9 0 9 1 mm 0 354 0 358 in 8 3 mm 0 327 in 9 2 mm 0 362 in Special Tools Outside Circlip Pliers 57001 144 Oil Seal amp Bearing Remover 57001 1058 7570144ST C 7571058ST C Bearing Driver Set 57001 1129 7571129ST C Socket Wrench Hex 41 57001 1402 75714028T TRANSMISSION 9 11 Oil Seal Driver 70 57001 1506 7571506ST C Assembly Jig 57001 1631 875716315 6 Liquid Gasket TB1216B 92104 1064 Cup 879210645 6 9 12 TRANSMISSION Transmission Oil Vehicle operation with insufficient deteriorated or contaminated transmission oil will cause acceler ated wear and may result in transmission failure Transmission Oil Level Inspection NOTE Olf the vehicle has just been used wait several minutes for all the oil to settle down e Parkthe vehicle on level ground and tilt up the cargo bed e Unscrew the oil gauge A wipe its dipstick B dry and insert it into the filler opening but DO NOT SCREW IT IN e Pull
88. 7 875716275 6 Drive Pulley Holder 57001 1628 875716285 Driven Pulley Holder 57001 1630 ST571630ST 6 Liquid Gasket TB1215 92104 1065 879210655 5 8 CONVERTER SYSTEM Air Cleaner Air Cleaner Element Removal KAF400 A1 B1 C1 AAF BAF CAF Early Models e Remove Guard Plate see Frame chapter Wingbolts A Cap B e Remove Air Cleaner Element A e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the torque converter NOTICE If dirt gets into the torque converter excessive wear and loss of driving power may result KAF400AAF BAF CAF Later Models e Remove Guard Plate see Guard Plate Removal in the Frame chapter Clamps A Unhook Cap B e Remove Air Cleaner Element A e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the torque converter If dirt gets into the torque converter excessive wear and loss of driving power may result Air Cleaner Element Cleaning Inspection e Refer to the Converter System in the Periodic Mainte nance chapter CONVERTER SYSTEM 5 9 Air Cleaner Air Cleaner Housing Removal e Remove Air Cleaner Element see Air Cleaner Element Removal Air Duct A Air Cleaner Housing Bolts B Air Cleaner Housing C e After removing the housing stuff pieces of lint free c
89. 7 Brake Panel Assemblies Brake Panel Assembly e Install for Rear Brake Panel New Gasket A e Install for Rear Brake Panel Parking Brake Cable Parking Brake Cable Bracket A Parking Brake Cable Bracket Nut B OHold the bolt C and tighten the nut NOTICE Do not turn the bolt The bolt is engaged by the spline in the brake panel When installing the cable tighten the nut only e Apply high temperature grease Contact Points A of Brake Panel and Brake Shoes e Install Shoe A ODo not attach greese and or oil to the surface of the brake shoes e While pushing the shoe hold down spring B turn the pin C 90 and install the spring e Install Linkage Springs A Parking Brake Lever Linkage B Shoe Spring C 12 18 BRAKES Brake Panel Assemblies e Install Shoe A e Install Shoe A e While pushing the shoe hold down spring B turn the pin C 90 and install the spring e Pry the ratchet lever A with a screwdriver B to reset the shoe clearance adjuster in its original position A Original Position of Ratchet Lever B Ratchet Lever e Apply liquid gasketto around A of shoe hold down spring pin heads e Install Brake Pipe and Brake Pipe Nipple B e Tighten Torque Brake Pipe Nipple 18 N m 1 8 kgf m 13 ft Ib e Install Brake Drum see Brake Drum Installation Brake Panel Assemblies BRAKES 12 19 e Bleed the brake line see Brake Line A
90. 75 mm 1 9669 1 9675 in Service Limit 49 93 mm 1 966 in e Measure the inside diameter A of the camshaft bearing on the crankcase at several points Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Standard 20 000 20 013 mm 0 7874 0 7879 in Service Limit 20 07 mm 0 790 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Standard 50 000 50 025 mm 1 9685 1 9695 in Service Limit 50 09 mm 1 972 in KG05014BS1 C KG05013BS1 C Cylinders and Pistons ENGINE BOTTOM END 8 11 Piston Removal e Remove Crankcase Cover see Crankcase Cover Removal Camshaft see Camshaft Tappet Removal Balancer Shaft see Balancer Shaft Removal e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod cap B NOTE ONote the position of the connecting rod caps for rein stalling the caps e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder e Remove one of the piston pin snap rings A with needle nose pliers e Remove the piston by pushing the piston pin A out the side from which the snap ring was
91. 9 7 8 L Pilot Jet 0 70 0 07 6 1 in Ib Pilot Jet Plug 2 5 0 25 22 Main Jet 2 0 0 20 17 in lb Drain Screw 2 0 0 20 17 in lb Float Chamber Bolt 9 8 1 0 87 Panel Cover Bolts 4 4 0 45 39 in Ib Control Panel Bolt 8 8 0 90 78 in lb Plate Connection Bolts 8 8 0 90 78 in lb Control Panel Mounting Bolts 20 2 0 14 Governor Arm Nut 7 4 0 75 65 in Ib Fuel Pump Mounting Bolts 5 4 0 55 48 Fuel Pump Bracket Bolt 54 0 55 48 in Ib Breather Mounting Bolt 8 8 0 90 78 Breather Bracket Bolt 15 1 5 11 Breather Hose Clamp Mounting Bolt 5 5 0 56 48 in Ib Engine Top End Cylinder Head Cover Bolts 6 9 0 70 61 in Ib Cylinder Head Bolts 37 3 8 27 S Engine Shroud Bolts 5 9 0 60 52 in lb Valve Adjusting Nut Lock Screw 6 9 0 70 61 in Ib Rocker Arm Bolts 28 2 9 21 Exhaust Pipe Clamp Nuts 20 2 0 14 S Muffler Clamp Nuts 31 3 2 23 S Muffler Mounting Bolts 31 3 2 23 S Converter System Drive Pulley Bolt 94 9 6 69 R Drive Pulley Cover Bolts 23 2 3 17 Spider 275 28 203 PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Fastener Remarks Weight Pin Nuts 4 61 in Ib Driven Pulley Bolt 52 Deflection Bolts 80 in Ib Driven Wear Shoe Mounting Screws 9 7 mb Converter Cover Bolts i 39 in lb Converter Cover Bolts KAFA00AAF BAF CAF Later Models SR Converter Case Front Bolts 26 5 mm s 14 Converter Case Rear Bolts 25 mm 14 Converter Case Cover Screws 5 2 44 in Ib Bracket Bolts 78 in lb Ai
92. A Clamps B 1611008851 C Fuel Tank Cleaning Inspection WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank and drain it e Remove the fuel level gauge A e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Dry the tank with compressed air e Visually inspect the gaskets on the fuel level gauge and fuel tank cap for any damage Replace the gaskets if they are damaged FUEL SYSTEM 3 29 Evaporative Emission Control System California Model KAF400ABF ACF BBF BCF US and Canada Models The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped AL though no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this
93. A and let the oil drain completely x lf the oil filter is to be changed replace it with new one See Oil Filter Replacement e Replace the gasket with a new one e After the oil has completely drained out install the drain plug with the gasket Torque Engine Oil Drain Plug 20 N m 2 0 kgf m 14 ft Ib e Slowly and evenly fill the engine with a good quality oil as specified in the table Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE10W 40 Capacity 0 85 L 0 9 US qt when filter is not removed 1 4 L 1 5 US qt when filter is removed Oil Level Between H and L marks on dipstick NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Thoroughly warm up the engine and check for oil leakage and the oil level see Oil Level Inspection in the Engine Lubrication System chapter PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Oil Filter Replacement e Drain the engine oil e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 OWhen unscrewing the oil filter co
94. B and cable holder C e Put the shift lever A in the 4WD position e Push the shift shaft lever A to the forward 4WD Posi tion and make the engagement of the shifter maximum while turning the propeller shaft by hand e Turn the nut B with fingers and pull slightly the inner cable and tighten the nut C e Put the shift lever in the 2WD position e Confirm to return the shift shaft lever to 2WD position 2WD 4WD Shift Cable Lubrication Whenever the shift cable is removed lubricate the cable as follows e Apply a thin coating of grease to the cable ends OThe cable may be lubricated by using a pressure cable lubricator with an aesol cable lubricant 108001851 C 6604011451 C 9 32 TRANSMISSION 2WD AWD Shift Mechanism KAF400 A C 2WD AWD Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely A within the cable housing x If the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable 2WD AWD Shift Mechanism Removal e Refer to Bevel Gear Case in the Final Drive chapter 2WD 4WD Shift Mechanism Inspection e Visually inspect Dogs on Shifter A Shifter Groove B Dogs on Driven Bevel Gear C Shifter Block D x If they are damaged or worn excessively replace them Shifter Block Outside Diameter Standard 13 95 14 00 mm 0 549 0 551 in Service Limit 13 8 mm 0 543 in Shifter Groove Width
95. C 10 Bracket KAF400 A C 11 Clamp KAF400 A C 12 Grease Seals KAF400 A C 13 KAF400 A1 A9F B1 B9F C1 C9F Models AG Apply lithium grease NLGI Grade No 2 L Apply a non permanent locking agent R Replacement Parts NIOJ 12 6 BRAKES Specifications Brake Pedal Free Play Brake Drums Brake Drum Inside Diameter Brake Panel Assemblies Brake Shoe Lining Thickness Parking Brake Lever And Cables Parking Brake Lever Travel 2 5 mm 0 08 0 20 in 165 00 165 16 mm 6 4961 6 5023 in 4 mm 0 16 in 8 12 notches clicks Item Standard Service Limit Brake Fluid Type DOT3 Fluid Level Between upper and lower level lines Brake Pedal 165 75 mm 6 526 in 1mm 0 04 in BRAKES 12 7 Special Tools Clutch Spring Compressor Brake Drum Pusher M18 x 1 5 57001 1162 57001 1261 T5711628T 875712615 6 Rotor Puller M16 M18 M20 M22 x 1 5 Brake Drum Holder 57001 1216 57001 1325 7571216ST C 875713255 C Brake Drum Remover Grease Seal Driver Set 57001 1260 57001 1629 S 875712605 6 875716295 12 8 BRAKES Brake Fluid Brake Fluid Recommendation e Use extra heavy duty brake fluid only from a container marked DOT3 Recommended Brake Fluid Type DOT3 A WARNING Brake fluid that is contaminated by moisture or dirt mixed or contains air has a lower boilin
96. Cover Bolts 6 9 0 70 61 in lb 2 Head Bolts 37 3 8 27 S 3 Engine Shroud Bolts 5 9 0 60 52 in lb 4 Valve Adjusting Nut Lock Screw 6 9 0 70 61 in Ib 5 Rocker Arm Bolts 28 2 9 21 6 Exhaust Pipe Clamp Nuts 20 2 0 14 S 7 Muffler Clamp Nuts 31 3 2 23 S 8 Muffler Mounting Bolts 31 3 2 23 S 9 Front Gasket P No 11061 0133 10 Rear Gasket P No 11061 0132 EO Apply engine oil M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence 4 4 ENGINE TOP END Exhaust System Exhaust System EXHAUST PIPE Non Catalyst P No 18088 0191 Mark Non Non Catalyst P No 18088 0192 Mark Non MUFFLER BODY SPECIFICATION Honercomb Type Catalyst U S A CALIF P No 18091 0487 Mark Non Honercomb Type Catalyst U S A CALIF P No 18091 0487 Mark Non MARKETING CODE KAF400A8FL KAF400C8FL KAF400B8FL 1E11002B ENGINE TOP END 4 5 Specifications Standard Cylinder Head Cylinder Compression Usable Range 340 590 kPa 3 5 6 0 kgf cm 50 85 psi 530 r min rpm Rocker Arm Push Rod Runout Cylinder Head Warp Valves Valve Clearance when cold 0 10 0 15 mm 0 0039 0 0059 in Valve Seating Surface Outside Diameter TIR 0 5 mm 0 02 in 0 03 mm 0 001 in Inlet 32 8 mm 1 291 in Exhaust 27 6 mm 1 087 in Width Inlet 1 1 1 7 mm 0 043 0
97. Disassembly 16 35 Starter Motor Assembly 16 37 Starter Motor Brush Inspection 16 38 Brush Spring Inspection 16 38 Armature Inspection 16 38 Yoke Assembly Inspection 16 40 Pinion Clutch Inspection 16 40 Starter Circuit Relay Inspection 16 40 Lighting System esent te 16 43 Headlight Beam Adjustment 16 43 Headlight Bulb Replacement 16 43 Tail Brake Light Replacement 16 46 Light Switch Bulb Replacement 16 47 Indicator Light Bulb Replacement 16 47 Elte 16 49 Brake Light Switch Inspection 16 49 Oil Temperature Sensor Inspection KAF400 A C 16 49 Oil Temperature Warning Indicator Control Unit Inspection 400 Switch Inspection Fuse Removal ees Fuse Installation Fuse Inspection 16 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 3 Exploded View T No Fastener Remarks N m kgf m ft Ib Fan Housing Bolts 5 9 0 60 52 mb Alternator Rotor 56 9 WIN 41 Spark Plug 22 Stator Coil Screws 3 4 Wire Lead Clamp Bolt 6 9 17 Starter Motor Terminal Nut 8 8 0 90 78 in lb gt N 16 4 ELECTRICAL SYSTEM Exploded View Ke 2 NS m 7 7 p 40 5 e GE d AY E IN Ni
98. INE BOTTOM END 8 23 Breather Breather Valve Removal e Remove the cylinder head assembly see Cylinder Head Assembly Removal in the Engine Top End chapter e Unscrew the breather valve screw A Breather Valve Installation e Install the reed valve A and back plate B Then tighten the breather valve screw C Torque Breather Valve Screw 3 4 Nim 0 35 kgf m 30 in Ib Install the cylinder head assembly see Cylinder Head As sembly Installation in the Engine Top End chapter Breather Valve Inspection e Remove the breather valve see Breather Valve Re moval Inspect the reed valve for breakage hair cracks or distor tion replace it if necessary e Inspect the back plate for damage or rough contact sur face replace it if necessary Inspect the valve seating surface The surface should be free of nicks or burrs e Align center of the valve seat with center of the reed valve and back plate then tighten the breather valve screw TRANSMISSION 9 1 Transmission Table of Contents Exploded View Specifications Special Tools Transmission Oil Transmission Oil Level Inspection Transmission Oil Change Transmission Transmission Case Removal Transmission Case Installation Drive Shaft Nut Removal 400 Drive Shaft Nut Installation
99. Ignition Timing 2 764 mm 1 335 mm 108 82 in 52 56 in 1 802 mm 70 94 in 1781 mm 70 12 in 1779 mm 70 04 in 1051 mm 41 38 in 999 mm 39 33 in 170 mm 6 69 in 155 mm 6 10 in 780 mm 30 71 in 768 mm 30 24 in AAF EUR 461 kg 1 017 Ib ACF EUR 462 kg 1 019 Ib CAL 463 kg 1 021 Ib AAF US CA 461 kg 1 017 Ib ABF US CA 462 kg 1 019 Ib ACF US CA 463 kg 1 021 Ib CAF 467 kg 1 030 Ib CAF CAL 469 kg 1 034 Ib 203 kg 448 Ib US 204 kg 450 Ib CAL 204 kg 450 Ib BAF BBF EUR 432 kg 953 Ib BAF US CA 432 kg 953 Ib BBF US CA BCF EUR 433 kg 955 Ib CAL BCF US 434 kg 957 Ib BAF EUR 183 kg 404 Ib BAF US CA 183 kg 404 Ib BBF BCF US CA 184 kg 406 Ib CAL 184 kg 406 Ib 258 kg 569 Ib AAF CAL 259 kg 571 Ib CAF 264 kg 582 Ib CAF CAL 265 kg 584 Ib 15 5 L 4 1 US gal 249 kg 549 Ib CAL BCF 250 kg 551 Ib 1 044 x 900 x 245 mm 41 10 x 35 43 x 9 65 in 3 3 m 10 83 ft 4 stroke OHV 2 valves 1 cylinder Positive air cooled 82 x 76 mm 3 23 x 2 99 in 401 cm 24 47 cu in 8 6 8 3 9 9 KW 13 5 PS 4 000 r min rpm 9 2 KW 12 5 PS 3 800 r min rpm 29 7 3 0 kgf m 21 9 ft lb 2
100. Inside Diameter Crankcase Side Crankcase Cover Side Cylinders and Pistons Piston Ring Groove Clearance Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Piston Diameter Cylinder Inside Diameter Cylinder Bore Out Round Piston Cylinder Clearance Crankshaft and Connecting Rods Connecting Rod Bend Connecting Rod Twist 29 955 30 045 mm 1 179 1 183 in 29 955 30 045 mm 1 179 1 183 in 19 967 19 980 mm 0 7861 0 7866 in 49 959 49 975 mm 1 9669 1 9675 in 20 000 20 013 mm 0 7874 0 7879 in 50 000 50 025 mm 1 9685 1 9695 in 0 04 0 08 mm 0 0016 0 0031 in 1 47 1 49 mm 0 0579 0 0587 in 0 15 0 40 mm 0 0059 0 0157 in 0 23 0 48 mm 0 0091 0 0189 in 0 25 0 75 mm 0 0098 0 0295 in 18 995 19 000 mm 0 7478 0 7480 in 19 004 19 015 mm 0 7482 0 7486 in 19 010 19 021 mm 0 7484 0 7489 in 81 935 81 955 mm 3 2258 3 2266 in 81 97 81 99 mm 3 2272 3 2279 in 0 015 0 055 mm 0 0006 0 0022 in 29 86 mm 1 176 in 29 86 mm 1 176 in 19 94 mm 0 785 in 49 93 mm 1 966 in 20 07 mm 0 790 in 50 09 mm 1 972 in 0 18 mm 0 0071 in 1 40 mm 0 0551 in 0 7 mm 0 028 in 0 8 mm 0 031 in 1 0 mm 0 039 in 18 96 mm 0 746
101. KAF400A9F JK1AF400AAB601001 JK1AFEB1009B518001 2009 KAF400B9F V 4AF400BBB603001 2009 KAF400C9F JK1AFEC109B511001 JK1AFEA10AB548501 2010 KAF400AAF K1AF400AAB601601 JK1AFEB10AB519601 2010 KAF400BAF Jk 1AF400BBB602101 2010 KAF400CAF JKTAFEC1DAB512601 JK1AFEA10BB551001 2011 KAF400ABF JK 1AF400AAB601901 JK1AFEB10BB520801 2011 KAF400BBF JK1AF400BBB602401 JK1AFEA1DCB557101 2012 KAF400ACF JK1AF400AAB602501 JK1AFEB1OCB522401 2012 KAF400BCF JK1AF400BBB602801 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1349 10 Printed in Japan
102. Lead Connector A e Remove Starter Motor see Starter Motor Removal Woodruff Key A Stator Coil Screws B Stator Coil C 16 24 ELECTRICAL SYSTEM Charging System Alternator Rotor and Stator Installation e Route the stator coil lead according to the Appendix chap ter e Install Stator Coil Stator Coil Screws e Tighten Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Clean A the inside of the alternator rotor and the end of the crankshaft or the taper will not fit snugly e Fit the rotor onto the crankshaft so that the woodruff key B fits in the groove C in the hub of the rotor e Insert the projections A of the cooling fan in the rotor recesses B e Insert the projection A of the plate in the groove B of the alternator rotor e Install Washer A and Alternator Rotor Bolt B OlInstall the washer as shown KH07008BS1 C Charging System ELECTRICAL SYSTEM 16 25 e Hold the alternator rotor with a suitable holder A e Tighten Torque Alternator Rotor Bolt B 56 N m 5 7 kgf m 41 ft Ib e Install Starter Motor see Starter Motor Installation Ignition Coil see Ignition Coil Installation e Connect Ignition Coil Lead Connector e Install Fan Housing OFit the stoppers A the fan housing e Tighten Torque Fan Housing Bolt 5 9 0 60 kgf m 52 in Ib e Install the removed parts Charging System Operational Inspection
103. Motor 11 Clamp 12 Carburetor 13 The distance between the fuel hose end and protector end is about 70 90 mm 2 76 3 54 in short side 14 Plug Side 15 Install the vacuum hose to this side 16 Throttle Cable 17 Fuel Hose Canister Fuel Tank 18 Canister 19 Fuel Hose Check Valve Fuel Tank KAF400A9F AAF B9F BAF C9F CAF 20 Check Valve KAF400A9F AAF B9F BAF C9F CAF 17 22 APPENDIX Cable Wire and Hose Routing Other than Europe Models KAF400ABF ACF BBF adm E AUN C Rai wan T Eer 59 A s 1808263885 C APPENDIX 17 23 Cable Wire and Hose Routing Fuel Filters Fuel Tank Bands Frame Pipe Fuel Hose Fuel Pump Vacuum Hose Fuel Hose Breather 10 Starter Motor 11 Clamp 12 Carburetor 13 The distance between the fuel hose end and protector end is short side 14 Plug Side 15 Install the vacuum hose to this side 16 Throttle Cable 17 Fuel Hose Canister Fuel Tank 18 Canister 19 Fuel Hose Check Valve Fuel Tank 20 Check Valve 21 Clamp 17 24 APPENDIX Cable Wire and Hose Routing 1808257884 C 1 Air Cleaner 2 Clamp 3 Air Duct 4 Clamp 5 Carburetor 6 Clamp 7 ACF BBF Models 8 Clamp 9 Drain Tube 10 Clamp 11 About 73
104. N Special Tool Assembly Jig 57001 1631 8 5716315 6 ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation Engine Removal e Disconnect Battery Terminal Cables see Electrical System chapter e Remove Cargo Bed Guard Plate see Frame chapter Exhaust Pipe see Engine Top End chapter Torque Converter Case see Converter System chapter Connecting Plate see Transmission Case in the Trans mission chapter Carburetor see Fuel System chapter Link Bracket A Starter Motor Cable B and Connector C Alternator Lead Connector D Ignition Coil Lead Connector E Oil Temperature Sensor Lead Connector F Hose G e Remove Engine Mounting Bolts and Nuts A both sides Engine Ground Lead B KAF400 A1 AAF B1 BAF C1 CAF Models KAF400ABF ACF BBF Models Engine Ground Lead Bolt A Engine Ground Lead B e Remove Engine A 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Installation x If the transmission case has not been removed start from the step 2 Step 1 e Mount the transmission case A with the rear axle brack ets B on the swingarm e Tighten the rear axle bracket bolts C with the specified torque Torque Rear Axle Bracket Bolts 34 N m 3 5 kgf m 25 ft Ib Step 2 e Replace the engine mounting nuts with new ones e Mount the engine D on the swingarm e Install the engine mount bolts and tighten the nuts
105. NOTICE The test light limits the current flow through the reg ulator rectifier Do not use an ammeter or multime ter in its place x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test Regulator Circuit Test 2nd Step e Connect the test light and the 12 V battery in the manner as specified in the Regulator Circuit Test 1st Step e Apply 12 V to BR terminal e Check G W1 and G W2 terminals respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test Regulator Circuit Test 3rd Step e Connect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step e Momentarily apply 24 V to BR terminal by adding a 12 V battery e Check G W1 and G W2 terminals respectively NOTICE Do not apply more than 24 V to the regulator recti fier and do not leave the 24 V applied for more than a few seconds or the unit will be damaged xIf the test light did not light when the 24 V was applied momentarily to the BR terminal the regulator rectifier is defective Replace it x 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
106. Periodic Maintenance Procedures Spark Arrester Cleaning AA WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark ar rester e Remove the drain plugs A from the muffler B e Apply the parking brake e In an open area away from combustible materials start the engine with the gear shift lever in the N neutral po sition e Raise and lower engine speed while tapping on the muf fler with a rubber mallet until the carbon particles are purged from the muffler A DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area Stop the engine e Install the drain plugs C California Model KAF400ABF BBF US and Canada Models Converter System Converter Air Cleaner Element Cleaning Inspec tion NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where ne
107. QUENCY Whichever First Regular Service comes Service first After 50 Every Every See gt h or 1 250 h 500 h or Page 000 km 5 000 10 000 OPERATION Every of use of use km ENGINE Throttle pedal play inspect e e 2 12 Fuel hoses and connections inspect e e 2 13 Fuel hose replace 5 years 2 13 Idle speed adjust e e 2 14 Fuel system cleanliness inspect e 2 14 Air cleaner element clean e e 2 15 Fuel filter replace e 2 15 Evaporative emission control system function inspect California Model KAF400ABF e e 2 16 ACF BBF BCF US and Canada Models Valve clearance inspect e e 2 17 Spark arrester clean e 2 18 Converter air cleaner element clean e e 2 18 Converter dust or water clean 2 19 Converter drive belt inspect e 2 19 Converter driven pulley shoe inspect e 2 21 Engine oil change 1 year e e 2 22 Oil filter replace 2 23 Spark plug clean and gap e e 2 24 CHASSIS Wheel nuts tightness inspect e e 2 24 Tire wear inspect e e 2 25 Front final gear case oil and transmission oil 1 year 8 e 2 25 change 2 23 Brake fluid level inspect e 2 26 Brake fluid change 2 years 2 27 Brake pedal play inspect 2 28 S cylinder cup and dust seal 2 years 2 29 Brake hose and pipe inspect e o 2 30 Brake hose replace 4 years 2 30 Brake wheel cylinder assembly replace 2 years 2 31 Brake wear inspect e 2 33 Parking brake lever inspect e e 2 33 St
108. RING 14 3 Exploded View Torque No Fastener em kgfm ftlb Remarks 1 Steering Wheel Mounting Nut 54 5 5 40 R 2 Main Shaft Mounting Bolts 34 3 5 25 3 Intermediate Shaft Clamp Bolts 25 2 5 18 4 Steering Gear Assembly Bracket Bolts 54 5 5 40 5 Rack Guide Spring Cap Locknut 39 4 0 29 6 Tie rod Locknuts 44 4 5 32 7 Strut Clamp Nuts 98 10 72 8 End Nuts 34 3 5 25 9 Horn Switch KAF400 B1 B6F Europe Models 10 Horn Switch Contact KAF400 B1 B6F Europe Models 11 Other than Europe Model G Apply grease R Replacement Parts 14 4 STEERING Specifications Item Standard Service Limit Steering Wheel Steering Wheel Free Play 0 20 mm 0 0 79 in Steering Gear Assembly Tie Rod Length Distance Between Flange End and Locknut about 34 mm 1 34 in STEERING 14 5 Special Tools Inside Circlip Pliers Knuckle Joint Remover 57001 143 57001 1619 7T570143S8T C T5716198T C Outside Circlip Pliers Knuckle Joint Driver 57001 144 57001 1640 875701445 C T5716408T C Bearing Driver Set 57001 1129 7571129ST C 14 6 STEERING Steering Wheel and Main Shaft Assembly Steering Wheel Free Play Inspection e Refer to Steering Inspection in the Periodic Maintenance chapter Steering Wheel Centering e Test ride the vehicle xIf the steering wheel is not straight when the vehicle is tr
109. RIVE 11 25 Front Final Gear Case KAF400 A C Correct Tooth Contact Pattern No adjustment is required 1L04006B 5 Heel A Bottom B Top C Toe D Ring Gear E Pinion Gear F Incorrect Tooth Contact Patterns Example 1 11040078 ODecrease the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown above Repeat in 0 05 mm 0 002 in steps if necessary Heel A Bottom B Top C Toe D Ring Gear E Pinion Gear F Incorrect Tooth Contact Patterns Example 2 1L04008B Olncrease the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown above Repeat in 0 05 mm 0 002 in steps if necessary Heel A Bottom B Top C Toe D Ring Gear E Pinion Gear F 11 26 FINAL DRIVE Front Final Gear Case KAF400 A C Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged Differential Gear Inspection e Visually check the differential gears A for scoring chip ping or other damage Also inspect the differential pinion gear shaft B and gear housing C where the differential gears rub x If they are scored discolored or otherwise damaged re place them as a set Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by fee
110. S2 C 1L07004BS1 C 11 42 FINAL DRIVE Axles Front Axle Joint Boot Replacement KAF400 A C Outboard Joint Boot Removal e Remove Front Axle see Front Axle Removal Boot Bands A e Scrap the removed boot bands e Slide the joint boot B toward the inboard joint e Tap the bearing housing A straight B with a plastic ham mer to separate it from the shaft NOTICE Do not tap on the cage Be careful not get hurt when the housing comes out If the splined portion of shaft cracked or damaged during disassembling of outboard joint do not reuse the shaft e Remove Circlip A Boot B Small Band C Outboard Joint Boot Installation e Clean the axle shaft by wiping off the used grease on it e Wind the tape on the splines of the axle shaft in order to protect the joint boot e Install New Small Band A New Boot B OApply the special grease slightly on the inside of the new boot small diameter and install the boot on the axle shaft NOTICE Only the special grease that is included with the boot kit can be applied to the boots e Install New Circlip C 11078010 P Axles FINAL DRIVE 11 43 Apply the special grease slightly on the part A of the band installation in order to make easy to install the boot band e Tighten the small boot band B OTighten the boot band A and bend the tangs B securely to hold down the end of the band Place
111. Seat Belt Removal e Remove Seat Belt Mounting Bolts A Seat Belts B Seat Belt Buckles C Seat Belt Installation e Tighten Torque Seat Belt Mounting Bolts 34 3 5 kgf m 25 ft Ib KAF400ACF BCF Models e Install Seat Belt Mounting Bolts A 40 60 B View C C IPO3009BS2 C 15 16 Control Panel Control Panel Removal e Remove Front Cargo Compartment see Front Cargo Compart ment Removal e Disconnect Ignition Switch Lead Connector A Power Outlet Connector Lead Connectors B e Disconnect Hour Meter Lead Connector A Oil Temperature Warning Indicator Light Lead Connec tors B Parking Brake Indicator Light Lead Connector C Light Switch Lead Connector D e Remove Snap Pins A and Pins Glove Compartment Cover B e Remove Control Panel Screws A and Collars Control Panel B FRAME 15 17 Control Panel Glove Compartment Removal e Remove Control Panel see Control Panel Removal Screws A Glove Compartment B 15 18 FRAME Front Cargo Compartment Front Cargo Hood Removal e Remove Snap Pins A Washer B Mounting Pins C Lever e Remove Snap Pin A Mounting Pin B Front Cargo Hood C Front Cargo Compartment Removal e Remove Screws A and Collars e Remove Screws A and Collars e Remove Screws A and Collars Quick Rivet B Front Cargo Compartment FRAME 15 19 e Remove Qui
112. Time at Rates Shown 1008002892 C Battery Troubleshooting Guide Good Battery Suspect Battery Action i D Plates Chocolate color white sulphated plates Replace 7 gray broken or corroded iment to plat Sediment none or small amount sog Replace causing short Voltage above 12 6 V below 12 6 V Test charge Electrolyte Level between upper and lower level lines below lower level line Fill and test charge Specific Gravity above 1 240 in all cells no two cells more than 0 020 different below 1 100 or difference of more than 0 020 between two cells Test charge Battery ELECTRICAL SYSTEM 16 21 Battery Test Charging x If the battery is suspected of being defective sulfated or unable to take a charge consult the table e To test charge a battery perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below Special Tool Hand Tester 57001 1394 x If the battery voltage suddenly jumps to over 13 V just af ter the start of charging the plates are probably sulfated good battery will rise to 12 V immediately and then grad ually go up to 12 5 or 13 V in about 30 min to an hour after the start of charging xIf one cell produces no gas bubbles or has a very low specific gravity it is probably shorted x If there does not appear to be enough sediment in a cell to short the plates but that cell has a very low specific gravity af
113. able A first and then the positive cable B e Remove Battery Holder C e Take out the battery D Battery Installation e Check that the rubber damper A is properly in place e Check that the rubber damper B under the battery holder C is properly in place e Putthe battery on the damper so that the positive terminal faces forward e Install Battery Holder Battery Holder Rods D e Route the battery bent hose E through the hole F in the floor board 1908004851 C e Connect the positive cable first and then connect the negative cable e Put a light coat of grease on the terminals to prevent cor rosion e Install Positive Terminal Cover Red Electrolyte Level Inspection e Refer to the Electrical System in the Periodic Mainte nance chapter Electrolyte Specific Gravity Inspection e Refer to the Electrical System in the Periodic Mainte nance chapter Charging Condition Inspection e Refer to the Electrical System in the Periodic Mainte nance chapter 16 18 ELECTRICAL SYSTEM Battery Initial Charging A DANGER Batteries produce an explosive gas mixture of hy drogen and oxygen that can cause serious injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This proce dure prevents sparks at the battery terminals which could ignite any battery gases
114. acer 54 3 1 0 High Gear D e Remove Spacer 54 3 x 1 0 A Needle Bearing B Low Gear C Needle Bearing D TRANSMISSION 9 19 Transmission Case e Remove Needle Bearing A Washer B 9 20 TRANSMISSION Transmission Case Transmission Case Assembly e Assemble the right transmission case as shown Right Transmission Case A Ball Bearing B Oil Seal C 6 mm 0 24 in D Ball Bearing E Seal Side F Ball Bearing G Ball Bearing H Oil Seal I 29 5 mm 1 16 in J Cover K Cover Screws L e Tighten Torque Cover Screws 4 0 N m 0 40 kgf m 35 in Ib oc Je i 14110028482 TRANSMISSION 9 21 Transmission Case e Assemble the left transmission case as shown Left Transmission Case A Ball Bearing B Ball Bearing C Seal Side D Ball Bearing E Bearing Holder F Refer to the following Shifter G Differential Shift Shaft H Shift Shaft Stop Bolt I Ball Bearing J Olnstall the ball bearing J after assembling the shifter G deferential shift shaft H and shift shaft stop bolt I Oil Seal K 13 mm 0 51 in L Governor Shaft M Long Side N 32 mm 1 26 in O Cover Screws P e Tighten Torque Cover Screws 4 0 N m 0 40 kgf m 35 in Ib 5 1411012803 C 9 22 TRANSMISSION Transmission Case OApply a non permanent locking agent Bearing Holder F Olnstall the bearing holder so that the deep recess A faces ou
115. ake Doesn t Hold Air in the brake line Brake fluid leak Brake fluid deteriorated Primary or secondary cup trouble Master or wheel cylinder scratched inside Brake not properly adjusted Lining overworn or worn unevenly Drum worn unevenly or scored Oil grease on lining and drum Dirt water between lining and drum Overheated brakes APPENDIX 17 5 Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator Rectifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator Rectifier trouble Battery trouble 17 6 APPENDIX Cable Wire and Hose Routing 1808043894 C Band Brake Panel Breather Hose Accessory Connector Power Outlet Lead Ignition Switch Lead Hour Meter Parking Brake Indicator Light Lead Oil Temperature Warning Indicator Light Lead KAF400 A C Horn Switch Lead Europe Model Light Switch Lead 10 Green Tape Left Side 11 Head Light Lead 12 Front Final Gear Case Breather Hose KAF400 A C 13 Hour Meter Lead 14 Parking Brake Indicator Light Lead 15 Oil Temperature Warning Indicator Light Lead KAF400 A C O CON OO ONS APPENDIX 17 7 Cable Wire and Hose Routing Li DETAIL DETAIL 1808044884 C Connector Cover Band Taping All Aro
116. al Gear Case Guard Removal e Remove Bolts A e Remove Bolts A Front Final Gear Case Guard B Front Final Gear Case Guard Installation e Install Front Final Gear Case Guard A Bolts B IP11000BS1 C Bottom Guard Removal e Remove Bolts A Bottom Guard B 15 28 FRAME Guard and Cover Bottom Guard Installation e Install Dampers A Bottom Guard B Bolts C Transmission Case Guard Removal e Remove Bolts A Transmission Case Guard B Transmission Case Guard Installation e Install Transmission Case Guard A Bolts B Center Cover Removal e Remove Quick Rivets A Center Cover B Center Cover Installation e Install Center Cover A Quick Rivets B IPUIBO IP11003BS1 C Guard and Cover FRAME 15 29 Side Covers Removal e Remove Quick Rivets A Screws B and Collars Bolts C and Collars Right Side Cover D e Remove Quick Rivets A Screws B and Collars Bolts C and Collars Left Side Cover D Side Covers Installation e Install Right Side Cover A Quick Rivets B Screws C and Collars D Bolts E and Collars D e Install Left Side Cover A Quick Rivets B Screws C and Collars D Bolts E and Collars D Cooling Fan Guard Removal KAF400A9F AAF B9F BAF C9F CAF e Install Band A Quick Rivets B Screws C and Collars D Flap E Screws F Cooling Fan Guard
117. ampers Bottom 1 040178 52 15 22 FRAME e Install Cargo Bed Rubber Dampers A and B e Install the small damper A on the center of the cargo bed rubber dampers B as shown C 2 mm 0 08 in 1 04003851 C e Grease Cargo Bed Mounting Pins e Install Cargo Bed Cargo Bed Mounting Pins Snap Pins e Install Rear Fender A Collars B Bolts C Clamp Nut D Screw E Cargo Bed Latch Position Inspection e Cargo bed latche A must rest securely on the cargo bed hooks B without rattling xIf there is rattling or not snug enough adjust the latch positions FRAME 15 23 Cargo Bed Cargo Bed Latch Position Adjustment e Loosen the mounting bolts A e Reposition the latch B to the suitable place by sliding within the ellipse bolt holes e Retighten the mounting bolts 15 24 FRAME Front and Rear Bars Front Bar Removal e Remove Front Bar Mounting Bolts Lower A Front Bar Mounting Bolts Upper B Washers and Nuts Front Bar C Front Bar Installation e Replace the front bar mounting nuts with new ones e Tighten Torque Front Bar Mounting Bolts Lower A 98 10 kgf m 72 ft lb Front Bar Mounting Bolts Upper B 44 N m 4 5 kgf m 32 ft lb Washers C Nuts D Rear Bar Removal e Remove Front Bar Mounting Bolts Upper A Washers and Nuts e Tilt up the cargo bed e Remove Air Ducts
118. and slide the snap ring C on the shaft OUsing the pipe D special tool push the snap ring in the groove E of the shaft e Install Ball Bearing A 1105005851 C 1LOSO006BS1 C 1LOSO08BS1 C 11 30 FINAL DRIVE Bevel Gear Case KAF400 A C Apply grease to the oil seal lip and install it e Install Snap Ring A Special Tool Snap Ring Guide 22 57001 1634 Olnstall the snap ring on the cap B of the snap ring guide OSlide the snap ring A until the ring gets to the body B of the snap ring guide ORemove the cap from the body OCover the body A on the driven bevel gear shaft and insert the snap ring B in the groove C of the shaft Drive Bevel Gear Removal e Remove Driven Bevel Gear Assembly Driven Bevel Gear Re moval e Remove Rear Brake Panels see Brakes chapter Rear Shock Absorbers see Suspension chapter Left Rear Axle Bracket and Axle Shaft see Rear Axle Removal e Install Bevel Gear Holder A Special Tool Bevel Gear Holder 57001 1638 e Set the Differential Lock position e Remove Drive Bevel Gear Nut B Washer Drive Bevel Gear C Shim Bevel Gear Case KAF400 A C FINAL DRIVE 11 31 Drive Bevel Gear Installation e Check and adjust the bevel gear backlash when any of the backlash related parts are replaced see Bevel Gear Adjustment e Install Shim A for Gear Backlash Drive Bevel Gear B Washer C take
119. ar the working areas Do not use gasoline or low flash point solvents to clean the element 1807002BS1 C PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Remove the air cleaner element see Converter System chapter e Separate the foam element A from the paper element B e Clean the foam element in a bath of a high flash point solvent and then squeeze it dry in a clean towel Do not wring the element or blow it dry the element can be damaged e Inspect the foam element for damage If it is torn punc tured or hardened replace it NOTE OReplace the foam element after cleaning it five times or if it is damaged e Clean the paper element by tapping it lightly to loosen dust e Blow away the remaining dust by applying compressed air from the inside to the outside from the clean side to the dirty side e Inspect the element material for damage If any part of the element is damaged the element must be replaced Converter Dust or Water Drain Cleaning e Remove the drain plug A on the bottom of the converter cover to expel dust and or water accumulated inside e After the draining insert the drain plug until the flange of the plug contacts on the face B of the cover ODo not apply grease to oval line part C of the plug when installing it However the soapy water is permitted Converter Drive Belt Inspection e Remove the driver belt see Converter System chapter
120. ary LSD Clutch Plate Inspection e Visually inspect the friction plates and steel plates to see if they show any signs of seizure overheating or uneven wear x If any plates show signs of damage or if the friction plates have worn replace the friction plates and steel plates as a set Outside Friction Plate Thickness A Standard 1 3 1 4 mm 0 051 0 055 in Inside Friction Plate Thickness B Standard 1 7 1 8 mm 0 067 0 071 in HK11002BS1 C Front Final Gear Case KAF400 A C FINAL DRIVE 11 19 Pinion Gear Unit Disassembly e Remove the pinion gear unit see Front Final Gear Case Disassembly e Holding the pinion gear unit with the pinion gear holder A unscrew the pinion gear nut B Special Tool Pinion Gear Holder m1 0 57001 1281 e Remove the ball bearing as necessary Special Tool Bearing Puller 57001 135 Pinion Gear Unit Assembly e The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be re placed as a set e Visually inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a bearing re place the bearing e Be sure to check and adjust the pinion gear preload and the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment e Install Pinion Gear A Shim B Ball Bearing C
121. asure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer xIf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter Standard 43 004 43 015 mm 1 6931 1 6935 in Service Limit 43 04 mm 1 694 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference x If the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Standard 42 957 42 970 mm 1 6912 1 6917 in Service Limit 42 94 mm 1 691 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig A or on V blocks gauge OSet a dial gauge B against both bearing journals OTurn the crankshaft slowly to measure the runout The dif ference between the highest and lowest dial gauge read ings TIR is the amount of runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 002 in Crankshaft Main Bearing Journal Wear e Measure the diameter A of the crankshaft main journal x If the journal has worn past the service limit replace the crankshaft with a new one Crankcase Side Crankshaft Main Journal Diameter Standard 34 955 34 980 mm 1 37
122. aveling in a straight line do the following e Check the tie rod length and adjust it if necessary see Wheels Tires chapter e Remove the cap A and the horn switch Europe model and then loosen the steering wheel mounting nut B e Push the vehicle in a straight line with no one aboard and stop it without turning the steering wheel e Remount the steering wheel C so that it is straight ahead Torque Steering Wheel Mounting Nut 54 N m 5 5 kgf m 40 ft Ib Steering Wheel and Steering Shaft Removal e Remove see above Front Cargo Compartment see Frame chapter Wheel Cap and Horn Switch Europe model Steering Wheel Mounting Nut and Spring Washer Steering Wheel e Remove Europe model Screws and Horn Switch Contact Two Straps of Horn Switch Body Lead e Remove Main Shaft Mounting Bolts Washers and Nuts A Main Shaft Clamp Bolt B e Lift the main shaft C e Remove Steering Gear Shaft Clamp Bolt A e Lift the intermediate shaft B STEERING 14 7 Steering Wheel and Shaft Assembly Steering Wheel and Steering Shaft Installation e Grease Dust Cover Lips A e Connect the intermediate shaft A to the main shaft B with the steering gear pinion in any position e Mount the steering wheel on the main shaft temporarily e Adjust Steering Wheel Position Adjustment Steering Wheel Centering e Tighten Torque Intermediate Shaft Clamp Bolts C 25 2 5 kgf m 18 ft lb St
123. bel pa ee de 8 18 Connecting Rod Big End Crankpin Width Wear eese 8 18 Connecting Rod Big End Bearing Crankpin Wear pp 8 19 Crankshatt Ee EE 8 19 Crankshaft Main Bearing Journal 8 19 Balancer Shafi aa a a Meader 8 21 Balancer Shaft Removal pp 8 21 Balancer Shaft Installation ce efe t Te Tee oido 8 21 Balancer Shaft Bearing Journal 8 21 EI 8 22 Breather Valve Removal pp 8 23 Breather Valve Installation pp 8 23 Breather Valve Inspection 8 23 8 2 ENGINE BOTTOM END Exploded View Exploded View ENGINE BOTTOM END 8 3 No Fastener Torque Remarks N m kgf m ft Ib 1 Connecting Rod Big End Cap Bolts 5 9 0 60 52 in lb EO 2 Breather Valve Screw 3 4 0 35 30 in Ib 3 Oil Filter Joint 6 9 0 70 61 in Ib 4 Line Plugs 3 9 0 40 34 in lb L 5 Crankcase Cover Bolts 22 2 2 16 6 Oil Drain Plugs 20 2 0 14 EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence 8 4 ENGINE BOTTOM END Specifications Item Standard Service Limit Camshaft and Tappets Cam Lobe Height Inlet Exhaust Camshaft Journal Diameter Crankcase Side Crankcase Cover Side Camshaft Bearing
124. brake and return the lever to its rest position 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If the lever travel is not correct adjust it e Loosen the locknut A and turn the adjusting nut B to obtain the correct amount of lever travel e Tighten the locknut e Check the parking brake for good braking power and when released no brake drag WARNING Insufficient free play can cause brake heating and drag resulting in skidding and loss of control which could cause an accident resulting in serious injury or death Be sure the brake free play is adjusted to the specification NOTE Olf the parking brake lever travel cannot be adjusted with the adjusting nut at the lever use the adjusters A be hind the parking brake lever Be sure to adjust both the left and right cables evenly and then securely tighten the adjuster mounting nuts B Steering Steering Inspection e Check steering wheel free play A OSet the front wheels straight ahead Gently turn B the steering wheel left and right The steering wheel free play is the amount of travel in the steering wheel before the front wheels begin to turn Steering Wheel Free Play Standard 0 20 mm 0 0 79 in x If steering wheel free play is not correct inspect the fol lowing Steering Wheel Mounting Nut see Steering chapter Intermediate Shaft Clamp Bolts see Steering chapter Steering Gear Assembly Mounting Bracket Bolts
125. cessary the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them Armature Inspection e Inspect the surface of the commutator x If it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves 8 11061051 C e Measure the depth of the grooves between the commu tator segments x If the grooves are shallower than the specified limit un dercut the insulating material to the standard depth 0 5 to 0 8 mm 0 012 to 0 031 in using a thin file x If the grooves are only dirty clean them carefully Commutator Groove Depth Standard 0 5 0 8 mm 0 020 0 031 in Service Limit 0 2 mm 0 008 in KHO9O13BS1 Bad A Segment B Good C 0 2 mm 0 008 in limit D Mica E Electric Starter System ELECTRICAL SYSTEM 16 39 e Measure the commutator B outside diameter A at sev eral points x If the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Standard 28 mm 1 102 in Service Limit 27 mm 1 063 in e Support the armature in an alignment jig at each end of the shaft as shown Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout runout is more than the service limit replace the ar mature with a new one Commutator Runout Serv
126. ch to secure it Apply grease to the oil seal lips and install it in the gear case Oil Seal A e Install Circlip B second groove C as shown Special Tool Outside Circlip Pliers 57001 144 Differential Unit Disassembly e Remove Differential Unit see Front Final Gear Case Disassem bly Differential Gear Housing Bolts A Differential Gear Unit B 048026 P 11 16 FINAL DRIVE Front Final Gear Case KAF400 A C e Remove Bevel Gear A e Remove Inside Friction Plates A Steel Plate B Outside Friction Plate e Remove Clutch Springs A Washer B e Remove Clutch Spring Shims A e Remove Spring Pins A Pinion Shaft B Bevel Gears C Collar D Washer E 1L04013BS1 C FINAL DRIVE 11 17 Front Final Gear Case KAF400 A C Differential Unit Assembly e Inspect the LSD clutch plates and see LSD Clutch Plate Inspection and other differential unit parts Replace any damaged parts e Apply specified gear oil to the differential unit parts e Note direction and position of the friction plates and clutch spring Clutch Spring Shims A Washer B Clutch Springs C Outside Friction Plate D Steel Plate E Inside Friction Plate F e Install the bevel gear A so that the teeth B fit in the grooves C fit e Install the LSD clutch case A on the ring gear B OAlign the bolt holes C e Install the differential gear unit A on the LSD
127. ck Rivet A Front Cargo Compartment B Front Cargo Compartment Installation e Install Screws 6 x 16 mm 0 24 x 0 63 in A Collars 6 mm 0 24 in B Screws 6 x 2 mm 0 24 x 0 08 in C Washers D Well Nuts E Quick Rivets F Collars 4 mm 0 16 in G IPO9000BS2 C 15 20 FRAME Cargo Bed Cargo Bed Removal e Remove Hook A unlock e Remove Rear Fender Mounting Screws A and Collars e Remove Rear Fender Mounting Screw A Rear Fenders B e Remove Tail Brake Light Lead Connectors A Tail Brake Light Mounting Bolts B Tail Brake Light Assembly C e Remove Snap Pins A Cargo Bed Mounting Pins B Cargo Bed C FRAME 15 21 Cargo Bed Assembly e Install Insulators A Supporting Hook B Bolt C and Nut D Supporting Hook Holder E Screw F KAF400 A1 A9F B1 B9F C1 C9F Models e Apply grease to the outside of the latch shaft A e Apply grease to the inside of the pipe B e Apply adhesive LOCKTITE 242 to the latch handle C e Install Latch Shaft Latch Handle Spring D Hook Wires E Washers F and Screws G Tail Gate Hook H Bolts I KAF400AAF BAF CAF Models e Apply adhesive LOCKTITE 242 to the damper e Install Damper A Hook Assy B Hook Assy bolts C Hook Wires D Screws E Tail Gate Hook F Bolts G Cargo Bed Installation e Apply adhesive agent Cargo Bed Rubber D
128. clearance see Spider Shoe Side Clearance Inspection xlIf the ramp weights A are damaged or worn replace them x If the pins B are damaged or worn replace them x If the rollers A are damaged or worn replace the spider B x If the washers C are damaged or worn replace the spi der x If the spring is worn or damaged replace the spring Spring Free Length A Standard 72 mm 2 83 in Spider Shoe Side Clearance Adjustment e Remove Drive Pulley see Torque Converter Removal Drive Pulley Cover and Spring see Drive Pulley Disas sembly e Set the drive pulley A without the spring onto the pulley holder B see Drive Pulley Disassembly Special Tool Drive Pulley Holder 57001 1628 e Temporarily install Dowel Pins 2 Drive Pulley Cover Two Bolts at dowel pins 806011851 C CONVERTER SYSTEM 5 21 Drive Pulley e Turn the movable sheave clockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at two points as shown D Arrow Mark Shoe Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in x The clearance is not within the specified range replace all shoes with standard shoes P No 49048 1090 see Drive Pulley Disassembly e Tighten the spider lightly by hand e Turn the movable sheave clockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at two posit
129. clutch case B OAlign the small holes C 11 18 FINAL DRIVE Front Final Gear Case KAF400 A C e Apply a non permanent locking agent Differential Gear Housing Bolts A e Finger tighten the all bolts first e Tighten Torque Differential Gear Housing Bolts 49 N m 5 0 kgf m 36 ft Ib LSD Clutch Torque Inspection e After assembling the differential unit and ring gear A check the LSD clutch torque e Insert both front axles in the unit Hold one of the front axles with a vise e Install the hub nut on the other axle e Measure the clutch torque using a torque wrench B Turn the wrench evenly OThe clutch torque is the mean torque reading during about a quarter turn of the wrench LSD Clutch Torque Standard 4 9 13 N m 0 5 1 3 kgf m 43 110 in Ib x If the clutch torque is out of the specified range disas semble the differential unit see Differential Unit and Ring Gear Disassembly and replace either of the clutch spring shim s e Also check the clutch plates and replace them as neces sary see Clutch Plate Inspection e To increase clutch torque increase the thickness of the shim s OChange the thickness a little at a time Clutch Spring Shims Thickness Part Number 1 0 mm 0 039 in 92180 1214 1 2 mm 0 047 in 92180 1215 1 4 mm 0 055 in 92180 1216 1 6 mm 0 063 in 92180 1217 1 8 mm 0 071 in 92180 1218 e Recheck the clutch torque and readjust as necess
130. cotter pin if the slots in the nut do not align with the cotter pin hole in the clamp bolt or joint tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slit goes past the nearest hole e Bend the cotter pin A over the nut B G6J04109BS1 OTighten the steering gear assembly bracket bolts evenly e Check Toe in of Front Wheels see Wheels Tires chapter Steering Gear Preload Adjustment e Loosen the locknut A e Tighten the rack guide spring cap B to 12 3 N m 1 3 kgf m 109 in lb of torque e Back off the cap 60 70 e Tighten the locknut while preventing the cap from turning Torque Rack Guide Spring Cap Locknut 39 N m 4 0 kgf m 29 ft lb Pinion C 1005000851 0 0 Spring Tie rod Length Adjustment e Refer to Toe in Adjustment in the Wheels Tires chapter Tie rod Length A Dust Boot Inspection e Refer to the Steering in the Periodic Maintenance chapter 14 10 STEERING Steering Knuckles Steering Knuckle Removal e Remove the steering knuckle together with the front sus pension arm see Front Suspension Arm Removal in the Suspension chapter e Install a suitable nut A on the stud of the tie rod end joint B and tap the nut to free the joint from the steering knuckle C OThe steering knuckle comes off the front suspension arm D Ste
131. ction e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Fuel System Cleanliness Inspection e Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Cargo Bed tilt up Guard Plate see Frame chapter Choke Cable Lower End A Breather Hose B Fuel Hose C Mounting Nuts D and Washers Intake Pipe E Choke Cable Bracket F e Remove Carburetor A Throttle Link B e After removing the carburetor stuff pieces of lint free clean cloth into the carburetor holder and the air cleaner duct to keep dirt out of the engine and air cleaner If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur 3 16 FUEL SYSTEM Carburetor Carburetor Installation e Install New Gasket A Insulator B Carburetor C OWhen installing the carburetor install the throttle link e Install New Gasket D Bracket E as shown Intake Pipe F Washers G and Mounting Nuts H Torque Carburetor Mounting Nuts 6 9 0 70
132. d repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man ual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main t
133. der running the other end of the hose into a container Brake Panel B NOTE OStart with the rear left or right wheel and finish with the front left or right wheel 15148043 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fill the reservoir with new brake fluid e Temporarily install the reservoir cap e Change the brake fluid as follows 1 Open bleed valve 2 Pump brake pedal and hold it 3 Close bleed valve 4 Release brake pedal e Tighten Torque Bleed Valves 8 0 N m 0 82 kgf m 71 in Ib e Repeat the previous step for each wheel e When brake fluid changing is finished add the fluid to the upper level in the reservoir e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage necessary bleed the air from the brake lines see Brakes chapter A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake pedal has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately e Install the removed parts Torque Master Cylinder Reservoir Cap 3 4 0 35 kgf m 30 in Ib Brake Pedal Play Inspection e Check brake pedal free play A Brake Pedal Free Play Standard 2 5 mm 0 08 0 20 in
134. der Nuts Exhaust Pipe and Muffler Clamp Bolt Muffler Mounting Bolts Throttle Pedal Pivot Clip Fuel Tank Holder Nuts Transmission Final Drive Axle Nuts and Cotter Pins Drive Shaft Bracket Mounting Nuts Transmission Shift Cable Upper End Clip Transmission Shift Lever Clamp Bolt Differential Shift Lever Pivot Clip Differential Shift Cable Upper End Clip Differential Shift Lever Mounting Nut Front Final Gear Case Mounting Nuts KAF400 A C Front Final Gear Case Bracket Bolts KAF400 A C Propeller Shaft Bearing Mounting Nuts KAF400 A C 2WD AWD Shift Lever Pivot Clip KAF400 A C 2WD AWD Shift Lever Mounting Nut KAF400 A C Transmission Shift Lever Pivot Clip Transmission Shift Cable Upper End Clip Transmission Shift Lever Mounting Nut Wheels Wheel Nuts Brakes Master Cylinder Mounting Bolts Master Cylinder Push Rod Clevis Pin Clip Parking Brake Lever Assembly Mounting Bolts Brake Pedal Pivot Shaft Cotter Pin Suspension Suspension Arm Pivot Bolts Strut Mounting Nuts Strut Clamp Nuts and Cotter Pins Shock Absorber Mounting Nuts Swingarm Joint Nut Swingarm Rod Bolts Swingarm Connecting Wire Bolts PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Steering Steering Wheel Mounting Nut Intermediate Shaft Clamp Bolts Tie rod End Nuts and Cotter Pins Tie rod End Locknuts Steering Knucle Pivot Nuts Steering Gear Assembly Mounting Bolts Suspension Arm Joint Nuts and Cotter Pins Main Shaft Mounting Bolts and Nuts Frame
135. e Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Camshaft seizure No fuel flow Fuel tank air vent obstructed Fuel pump trouble Fuel filter clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap not in good contact Spark plug incorrect Ignition coil trouble Ignition switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect Ignition coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Choke valve stuck closed Fuel level too high or too low Fuel tan
136. e or sparks this includes any appliance with a pilot light 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Tilt up the seat e Open the rubber damper A e Remove Clamps B and Fuel Hoses Fuel Filter C e Install the fuel filter A so that the arrow B on it shows the fuel flow from the fuel tank to the fuel pump e Install the clamps securely Evaporative Emission Control System Inspection California Model KAF400ABF ACF BBF US and Canada Models e Inspect the canister as follows OTilt up the seat ORemove the canister A and disconnect the hoses from the canister OVisually inspect the canister for cracks or other damage x If the canister has any cracks bad damage replace it with a new one NOTE OThe canister is designed to work well through the utility vehicle s life without any maintenance if it is used under normal conditions e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter Refer to the diagram of the evaporative emission control system in the Fuel System chapter too OWhen installing the hoses avoid sharp bending kinking flattening or twisting and run the hoses with a minimum of bending so that the emission flow will
137. e Apply molybdenum disulfide grease to the spline C of the propeller shaft e Apply grease to the oil seal lip D e Install O rings E Boot F Spring G Rear Universal Joint H ORefer to Propeller Shafts Assembly for universal joint installation e Insert the propeller shaft into the front universal joint I e Push the rear universal joint forward fully and install the propeller shaft rear end J on the bearing housing K e Install the O rings L on the rubber boot 1196003842 C FINAL DRIVE 11 37 Propeller Shafts KAF400 A C Propeller Shafts Assembly e Install the each yokes as the figure below Front Propeller Shaft B Bearing Housing C Rear Propeller Shaft D E OW 20 E 2 2 OW 1196004842 C Rear Propeller Shaft Removal e Remove Bottom Guard see Frame chapter Front Propeller Shaft see Front Propeller Shaft Re moval e Loosen the bearing housing bolts A as shown e Remove Yoke Stop Bolt A 11 38 FINAL DRIVE Propeller Shafts KAF400 A C e Push the universal joint A forward fully and remove the rear end from the bevel gear shaft B e Remove Rear Propeller Shaft C Rear Propeller Shaft Installation e Replace the yoke stop nut with a new one e When installing the cover A press the cover so that the distance between the cover surface and yoke end B is specified
138. e Ground Terminal A Accessory Fuse 10 A A Main Fuse 30 A B Battery C Starter Motor A Speed Sensor B Option Speed Meter A Option 16 14 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes in the electrical parts OAlways check battery condition before condemning other parts 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 allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the main switch is on or while the engine is run ning OBecause of the large amount of current never keep the main switch turned to the start position when the starter motor will not turn over or the current may burn out the starter motor windings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was brought on by some other item or items they too must be re
139. e Sensor KAF400 A C 5 4 0 55 48 in Ib Neutral Switch 15 1 5 11 Reverse Switch Europe Model 15 1 5 11 The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners of Engine Parts Threads dia Torque een Mark of Bolt Head RES Kin 6 4 3 9 4 9 0 40 0 50 35 43 in lb 6 7 8 9 8 0 80 1 0 69 87 in lb 6 9T 12 15 1 2 1 5 104 130 in Ib 8 4T 10 14 1 0 1 4 87 120 in lb 8 7T 18 22 1 8 2 2 13 16 10 14 17 10 29 33 Basic Torque for General Fasteners of Frame Parts Threads dia Torque mm N m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 8 7 9 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 14 10 26 34 2 6 3 5 19 25 12 44 61 4 5 6 2 33 45 Specifications PERIODIC MAINTENANCE 2 9 Item Standard Service Limit Fuel System Throttle Pedal Free Play Idle Speed 2 5 mm 0 08 0 20 in PH 1 100 1 250 r min rpm Fie Engine Top End Valve Clearance when cold 0 10 0 15 mm 0 0039 0 0059 in Converter System Belt Width Belt Deflection Wear Shoe Width 26 1 27 3 mm 1 03 1 07 in 22 32 mm 0 87 1 26 in
140. e Tighten Torque Drive Shaft Nut 137 N m 14 kgf m 101 ft Ib Special Tool Bevel Gear Holder 57001 1638 e Install the plug C until it is bottomed Special Tool Oil Seal Driver 670 57001 1506 Transmission Case Disassembly e Remove Drive Bevel Gear KAF400 A C see Final Drive chapter Drive Shaft Nut KAF400 B see Drive Shaft Nut Re moval Transmission Case see Transmission Case Removal e Remove Transmission Case Bolts A Transmission Case Right B 1405005851 C Transmission Case TRANSMISSION 9 17 e Remove Drive Shaft A Differential Gear Assembly B e Remove Positioning Bolt A Washer B Spring C Steel Ball D e Remove Pin A e Push up the shift shaft B e Remove the following parts at same time Transmission Shaft A Driven Shaft B Shift Rod C Reverse Chain D e Remove Shift Shaft A Snap Pins B Governor Shaft C Governor Assembly D see Fuel System chapter 9 18 TRANSMISSION Transmission Case e Using the socket wrench A remove the bearing holder B Special Tool Socket Wrench Hex 41 57001 1402 e Remove Circlip A of Transmission Shaft B Special Tool Outside Circlip Pliers 57001 144 e Remove Collar C Sprocket D e Remove Needle Bearing A Spacer B Shifter C e Remove Circlip Special Tool Outside Circlip Pliers 57001 144 e Remove Washer A Spacer B Spacer C Sp
141. e Transmission Oil Level Inspection in the Transmission chapter 6005040251 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning Inspection e Remove the spark plug see Electrical System chapter e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge xIf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap 9 0 0 0 9 9 9 0 9 2 N Spark Plug Gap 0 7 0 8 mm 0 028 0 032 in 5 AN 2 8 10010851 C Wheels Tires Wheels Nuts Tightness Inspection e Check the tightness of all the wheel nuts there are loose nut first loosen by 1 2 turn then re torque them to the specified torque Torque Wheel Nuts 34 N m 3 5 kgf m 25 ft Ib OTighten the wheel nuts 1 4 in a criss cross pattern 15128001 P PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Tire Wear Inspection e Examine the tire for damage and wear x the tire is cut or cracked replace it OLumps or high spots o
142. e backlash while pushing the driven gear shaft to rearward and turn the shaft clockwise and coun terclockwise while holding the drive bevel gear steady with the bevel gear holder The difference between the highest and lowest gauge readings is the amount of back lash x If the backlash is not within the limit replace the shim s at the drive gear To increase backlash decrease the thickness of the shim s To decrease backlash increase the thickness of the shim s Change the thickness a little at a time e Recheck the backlash and readjust as necessary Bevel Gear Backlash Standard 0 35 0 50 mm 0 0138 0 0197 in at driven bevel gear tooth FINAL DRIVE 11 33 Bevel Gear Case KAF400 A C Bevel Gear Case Backlash Related Parts D 1L05002BW3 C 1 Driven Gear Shaft 2 Ball Bearings 3 Drive Gear Shaft 4 Drive Gear Shim s 5 Drive Bevel Gear 6 Driven Bevel Gear Drive Gear Shims 4 0 15 mm 0 0059 in 92025 1688 0 5 mm 0 0197 in 92025 1689 0 6 mm 0 0236 in 92025 1690 0 7 mm 0 028 in 92025 1691 0 8 mm 0 031 in 92025 1692 0 9 mm 0 035 in 92025 1693 1 0 mm 0 0039 in 92025 1694 1 1 mm 0 0043 in 92025 1695 1 2 mm 0 0047 in 92025 1696 11 34 FINAL DRIVE Bevel Gear Case KAF400 A C Bevel Gear Inspection e Visually check the drive bevel gear A and the driven bevel gear B for scoring chipping or other damage Replace the bevel gear
143. e movable sheave bushings A into the movable sheave B using the special tool so that the end of bush ing are flush with the shoulder C in the holes Special Tool Bearing Driver Set 57001 1129 Driven Pulley Assembly e Install the wear shoes A on the movable sheave as fol lows OThe wear shoe must be installed so that the grooves B on the shoe faces inside e Apply a non permanent locking agent to the wear shoe mounting screws C e Tighten Torque Driven Wear Shoe Mounting Screws 1 1 N m 0 11 kgf m 9 7 in Ib e Hold the fixed sheave with the driven pulley holder Special Tool Driven Pulley Holder 57001 1630 e Install the spacer A on the fixed sheave B e Install Movable Sheave A Spring B Olnsert the spring end into the hole C on the movable sheave e Install the ramp A on the fixed sheave shaft e Insert the spring end B into the hole 2 on the ramp e Align the flat portions C of spline on the fixed sheave and ramp 17207013851 17776022 5 28 CONVERTER SYSTEM Driven Pulley e Put the circlip A on the ramp e Install the spring holder B e Push down the ramp halfway by tightening the nut C e Turn the movable sheave A counterclockwise 120 with the driven pulley holder B Special Tool Driven Pulley Holder 57001 1630 e Tighten the holder bolts A and hold the movable sheave B e Tighten the nut A until the groove
144. e shift rod A and shift fork B xIf the fork is bent replace the shift rod with a new one A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power C 90 Shift Fork Ear and Shifter Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width of the gear groove and shifter x If the thickness of a shift fork ear is less than the service limit the shift rod must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 2322 0 2362 in Service Limit 5 8 mm 0 228 in x If the groove is worn over the service limit the shifter must be replaced Shifter Groove Width A Standard 6 05 6 15 mm 0 2382 0 2421 in Service Limit 6 25 mm 0 2460 in 1J06005BS1 C Dutt 9 30 TRANSMISSION Transmission and Shift Mechanism Transmission and Shift Mechanism Inspection e Visually inspect Gears Dogs of Gear and Shifter x If they are damaged or worn excessively replace them Reverse Chain 20 Link Length B Standard 190 50 190 97 mm 7 500 7 518 in Service Limit 193 4 mm 7 614 in A Force C 1st Pin D 2nd Pin E 21st Pin 1J06006BS2 C GE11020181 2WD AWD Shift Mechanism KAF400 A C TRANSMISSION 9 31 2WD 4WD Shift Cable Adjustment e Put the shift lever A in the 2WD position e Install the 2WD 4WD shift cable A to the shift shaft lever
145. e snap rings as removal weakens and deforms them They could fall out and score the cylinder wall KE06045BS1 C KE06033BS1 C ENGINE BOTTOM END 8 13 Cylinders and Pistons e Apply engine oil to the piston skirt and the cylinder bore e Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 580 91 57001 1320 e Facing the arrow mark D on the top of the piston toward the alternator rotor side E NOTICE The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply engine oil to the inner surface A of the connecting rod big end B and caps C e Install the connecting rod big end caps in their original position on the connecting rod big ends by matching the marks D e Apply a small amount of engine oil to the thread and seat ing surface of the cap bolts E e Tighten the cap bolts Torque Connecting Rod Big End Cap Bolts 5 9 N m 0 60 kgf m 52 in Ib KE06036BS1 C e Install Camshaft see Camshaft Tappet Installation Crankcase Cover see Crankcase Cover Installation Piston Cleaning e Remove the piston and piston rings see Piston Re moval NOTICE Never cl
146. eads Portion D Two Washers e Install Driven Pulley Two Washers A as shown Transmission Case Side B Bolt Head Side C e Using the flywheel amp pulley holder A and attachments B tighten the driven pulley bolt C Special Tools Flywheel amp Pulley Holder 57001 1605 or 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Bolt 70 N m 7 1 kgf m 52 ft Ib To avoid damage to the converter case bolts transmission case transmission shaft oil seal cam ramp fixed sheave and movable sheave caused by overtightening the driven pulley bolt eBe sure to clean oil off the tapered portion of the transmission shaft and movable sheave eNever tighten the driven pulley bolt with an impact wrench Use a torque wrench e Install Drive Pulley A and Belt B NOTE OBe sure the printed information C faces the same di so the belt may rotate in the same direction as originally installed When installing a new belt install it so the printing can be read from outside the vehicle H 07008BS1 Torque Converter CONVERTER SYSTEM 5 13 e Replace the drive pulley bolt A with a new one e Install the two washers B and stepped washer C on the drive pulley bolt as shown e Install the drive pulley holder A see Torque Converter Removal Special Tool Drive Pulley Holder 57001 1620 e Tighten the drive pulley bolt B holding the drive pulley with t
147. ean the piston head with the engine assem bled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off the piston head with a scraper A KE08037B81 e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause damage e Clean the piston ring grooves A with a broken piston ring or other suitable tools Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement KE06038BS1 C 8 14 ENGINE BOTTOM END Cylinders and Pistons Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them xIf the ring grooves are worn unevenly or damaged re place both the piston and piston rings e Measure the clearance between the top and second rings and their grooves using a thickness gauge A xIf the piston ring groove clearance is greater than the specified value replace the piston Piston Ring Groove Clearance Standard Top Second 0 04 0 08 mm 0 0016 0 0031 in Service Limit Top Second 0 18 mm 0 0071 in NOTE OThe oil ring is a three piece assembled ring It is difficult to measure the ring groove clearance and thickness visually inspect only e Measure the piston ring thick
148. ecting Plate B e Remove Governor Cover A Transmission Shift Cable End Lever B Holder C e Remove Starter Motor Cable A and Connector B Hose C e Remove Starter Motor Mounting Bolts A Starter Motor B Starter Motor Installation e Clean the mating surface of the starter motor A and the crankcase B where the starter motor is grounded 16 34 ELECTRICAL SYSTEM Electric Starter System e Install the starter motor A to the engine as shown e Tighten Torque Starter Motor Mounting Bolts 17 N m 1 7 kgf m 12 ft Ib Starter Solenoid Inspection NOTE OBe sure the battery is fully charged e Remove Starter Motor see Starter Motor Removal e Disconnect the starter motor lead A e Connect the hand tester A and a 12 V battery to the starter motor solenoid B as shown OSet the hand tester to x1 O range connect the tester leads to the stud terminals C OConnect the battery Terminal to Solenoid Terminal D Terminal to Solenoid Body E x If the solenoid does not work as specified as follows the solenoid is defective Replace the solenoid Testing Solenoid Hand Tester Range x 1 Q Criteria When battery is connected click sound and 0 Q When battery is disconnected gt Q Starter Motor Inspection e Inspect the starter solenoid see Starter Solenoid Inspec tion e Hold the starter motor in a vise NOTICE Be careful not to deform the starter mo
149. ed when turned in This is to set the screw to its original position NOTE OA carburetor has different turns out of the pilot screw for each individual unit When setting the pilot screw use the turns out determined during disassembly Use the specifications in this manual only if the original num ber is unknown e Remove the pilot screw and set the pilot screw using a screwdriver e Install a new plug in the pilot screw hole of the carburetor body and apply a little bonding agent C to the circum ference of the plug to fix the plug Do not apply too much bonding agent to the plug or the pilot screw itself may be fixed 1607003851 C 3 22 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal e Tilt up the seat e Unhook the clamps A e Remove Air Cleaner Cover B e Loosen Clamp Screw A e Remove Mounting Screw B Air Cleaner Element C e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the car buretor and engine WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Air Cleaner Element Installation e Apply grease to the dust seal A e Install the e
150. ed with new ones e Clean any dirt and oil off the bevel gear teeth e Assemble the front final gear case see Front Final Gear Case Assembly Do not apply liquid gasket during ad justment OCheck the backlash during tightening of the ring gear cover bolts and stop tightening them immediately if the backlash disappears Then change the ring gear shim to a thinner one e Set up a dial gauge against a spline of pinion gear shaft to check gear backlash shown e To measure the backlash move the pinion gear back and forth while holding the front axle steady The difference between the highest and the lowest gauge reading is the amount of backlash x If the backlash is not within the limit replace the ring gear shims To increase backlash decrease the thickness of the shim s To decrease backlash increase the thick ness of the shim s OChange the thickness a little at a time e Recheck the backlash and readjust as necessary e Move the pinion gear shaft back and forth A Dial Gauge B Bevel Gear Backlash Standard 0 06 0 18 mm 0 0024 0 0071 in at pinion gear spline 11 22 FINAL DRIVE Front Final Gear Case KAF400 A C Front Final Gear Case Backlash Related Parts 1L04009BW3 C Front Final Gear Case Cover Differential Unit Ring Gear Right Shim Ball Bearings Ring Gear Ring Gear Case Ring Gear Left Shim Pinion Gear Pinion Gear Shim Orop
151. ee Play Adjustment e Refer to the Throttle Pedal Free Play Adjustment in the Periodic Maintenance chapter Full Throttle Pedal Position Adjustment e Loosen the locknut A e Screw in the throttle pedal stop bolt B e Depress the throttle pedal C until the throttle lever on the carburetor is in the fully opened position and keep its position e Turn the throttle pedal stop bolt until the bolt head lightly touches the bottom of the throttle pedal e Tighten the locknut securely Throttle Cable Installation e Lubricate the throttle cable before installation e Route the throttle cable correctly see Appendix chapter e Adjust Throttle Pedal Free Play Adjustment A WARNING Operation with incorrectly routed or improperly ad justed cable could result in an unsafe riding condi tion Be sure the cable is routed correctly and prop erly adjusted Throttle Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Main tenance chapter lubricate the cable e Refer to the General Lubrication in the Periodic Mainte nance chapter Throttle Cable Inspection e With the throttle cable disconnected at both ends the ca ble should move freely A within the cable housing xIf the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable 6004040281 3 8 FUEL SYSTEM Govern
152. eering inspect e e 2 34 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart FREQUENCY Whichever First Regular Service Service After 50 Every h or 1 250 h or 500 h or 000 km 5 000 km OPERATION of use of use kmofuse Steering joint dust boots inspect Seat belt inspect Battery inspect Brake light switch inspect General lubrication perform Bolts nuts and fasteners tightness inspect e Clean adjust lubricate torque or replace parts as necessary Service more frequently when operated in mud dust or other harsh riding conditions 2 4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket L Apply a non permanent locking agent to the threads MO Apply molybdenum disulfide oil the weight ratio of the mixture between engine oil and disulfide grease is 10 1 O Apply an oil to the threads seated surface or washer R Replacement Parts S Tighten the fasteners following the specified sequence SS Apply a silicone sealant to the threads Torque Fastener kgfm ftlb Remarks Fuel System Air Cleaner Housing Bolts 17 1 7 12 2 SCH Bolts KAF400ABF 55 0 56 48 in lb Carburetor Mounting Nuts 6 9 0 70 61 in Ib Choke Valve Screws 0 90 0 09 7 8 L Throttle Valve Screws 0 90 0 0
153. eering Wheel Mounting Nut 54 5 5 kgf m 40 ft Ib 1004002BS1 C Europe model e Install the horn switch A as shown 14 8 STEERING Steering Gear Assembly Steering Gear Assembly Removal e Remove Front Cargo Compartment see Frame chapter Front Wheels see Wheels Tires chapter Steering Wheel and Steering Shaft see Steering Wheel and Steering Shaft Removal Cotter Pins Tie rod End Nuts A and Tie rod Ends B from Steering Knuckles Olnstall a suitable nut on the stud of the tie rod end joint and tap the nut to free the joint from the steering knuckle NOTICE Do not loosen the tie rod end locknuts C or the toe in of the front wheels will be changed e Remove front view Screw A and Horn Ground Lead Terminal Steering Gear Assembly Bracket Bolts B and Brackets C e Remove Steering Gear Assembly A Steering Gear Assembly Installation e Adjust if necessary Steering Gear Preload Adjustment Tie rod Length Adjustment e Clean the tapered portion of the tie rod end joint and the tapered hole of the steering knuckle or the tapers will not fit snugly e Grease Tie rod End Joint Boot Sealing Surfaces A B Good C Bad 1005003851 e Tighten Torque Steering Gear Assembly Bracket Bolts 54 Nm 5 5 kgf m 40 ft Ib Tie rod End Nuts 34 N m 3 5 kgf m 25 ft lb STEERING 14 9 Steering Gear Assembly e Insert a new cotter pin A NOTE OWhen inserting the
154. el Gear Backlash Bevel Gear Case KAF400 A C Bevel Gear Backlash API GL 5 or GL 6 hypoid gear oil for LSD Limited Slip Differential gears SAE90 GL 6 or SAE140 GL 5 0 35 L 0 37 US qt Filler opening level 4 9 13 N m 0 5 1 3 43 110 1 3 1 4 mm 0 051 0 055 in 1 7 1 8 mm 0 067 0 071 in 0 5 Nm 0 05 4 4 in Ib or less 0 06 0 18 mm 0 0024 0 0071 in at pinion gear spline 0 35 0 50 mm 0 0138 0 0197 in at driven bevel gear tooth Special Tools Bearing Puller 57001 135 Outside Circlip Pliers 57001 144 875701355 C 7570144ST C Pinion Gear Holder m1 0 57001 1281 875712815 6 Socket Wrench 57001 1283 Socket Wrench Hex 48 57001 1401 875712835 6 875714015 FINAL DRIVE 11 9 Pinion Gear Holder m1 0 57001 1632 8757163297 6 Snap Ring Guide 20 57001 1633 875716335 6 Snap Ring Guide 22 57001 1634 Ce 875716345 Gear Holder 57001 1638 ST571638ST C Bevel Gear Holder 57001 1639 875716395 11 10 FINAL DRIVE Special Tools Liquid Gasket TB1216 92104 1063 879210635 6 Liquid Gasket TB1216B 92104 1064 879210645 6 Front Final Gear Case KAF400 A C FINAL DRIVE 11 11 Front Final Gear Case Oil Level Inspection e Remove Fill
155. el Hose Fuel Tank Canister 20 Fuel Hose Canister Air Cleaner Duct 21 Fuel Hose Canister Fuel Filter 22 Fuel Hose 23 Check Valve 24 KAF400A9F ACF B9F BCF C9F CAF Models 25 California Model KAFA00ABF ACF BBF US and Canada Models 26 KAF400ABF ACF BBF Models 27 California Model KAF400ABF BBF US and Canada Models M Apply molybdenum desulfide grease R Replacement Parts 3 6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Pedal and Cable Throttle Pedal Free Play 2 5 mm 0 08 0 20 in Choke Cable Choke Knob Free Play 0 1 mm 0 0 04 in Carburetor Idle Speed about 1 100 1 250 r min rpm Carburetor Specifications Make Type NIKKI 6C1026 Main Jet 112 Pilot Jet Slow Jet 54 Pilot Screw turns out 3 3 8 SSS Optional Parts Main Jet Altitude 0 500 m 0 1 600 ft 500 1 500 m 1 600 4 900 ft 1 500 2 500 m 4 900 8 200 ft 2 500 3 500 m 8 200 11 500 ft 3 500 4 500 m 11 500 14 800 ft Refer to page 5 29 for high altitude setting in the converter system 112 92063 7045 109 92063 7044 105 92063 7013 102 92063 7014 99 92063 2458 FUEL SYSTEM 3 7 Throttle Pedal and Cable Throttle Pedal Free Play Inspection e Refer to the Throttle Pedal Free Play Inspection in the Periodic Maintenance chapter Throttle Pedal Fr
156. enance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the products system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE xIndicates
157. ended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element e Remove Air Cleaner Element see Air Cleaner Element Removal Foam Element A Paper Element B e Clean the foam element in a bath of high flash point sol vent using a soft bristle brush e Squeeze it dry in a clean towel NOTICE Do not wring the element or blow it dry the element can be damaged e Inspect the foam element for damage x If it is torn punctured or hardened replace it NOTE OReplace the foam element after cleaning it five times or if it is damaged e Clean the paper element by tapping it lightly to loosen dust e Blow away the remaining dust by applying compressed air from the inside to the outside from the clean side to the dirty side e Inspect the element material for damage x If any part of the element is damaged the element must be replaced Fuel Filter Replacement A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flam
158. er A on the carburetor begins to turn the amount of choke knob travel is the amount of free play x If the free play is not correct adjust the choke cable Choke Knob Free Play Standard 0 1 mm 0 0 04 in Choke Knob Free Play Adjustment e Remove Guard Plate see Frame chapter e Loosen the mounting nuts A and slide the adjuster B until the cable has the proper amount of free play e Tighten the mounting nuts securely Choke Cable Installation e Lubricate the throttle cable before installation e Route the choke cable correctly see the Appendix chap ter e Adjust Choke Cable Free Play Adjustment A WARNING Operation with incorrectly routed or improperly ad justed cable could result in an unsafe riding condi tion Be sure the cable is routed correctly and prop erly adjusted Choke Cable Lubrication e Whenever the choke cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Main tenance chapter lubricate the cable e Refer to the General Lubrication in the Periodic Mainte nance chapter 3 14 FUEL SYSTEM Choke Cable Choke Cable Inspection e With the choke cable disconnected at both ends the ca ble should move freely A within the cable housing x If the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable 6004040281 C FUEL SYSTEM 3 15 Carburetor Idle Speed Inspe
159. er Cap A Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bot tom A of the filler opening B x If it is insufficient first check the front final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case e Be sure the O ring C is in place and tighten the filler cap Torque Front Final Gear Case Oil Filler Cap 29 N m 3 0 kgf m 22 ft lb Front Final Gear Case Oil Change e Refer to Final Drive section in the Periodic Maintenance chapter Front Final Gear Case Removal e Remove Front Guard Cover see Frame chapter Front Final Gear Case Oil drain see Front Final Gear Case Oil Change in the Periodic Maintenance chapter Front Axles see Front Axle Removal Loosen Front Final Gear Case Lower Mounting Bolts A e Remove Front Final Gear Case Mounting Bolt B and Nuts e Remove Bracket Bolts A Bracket B Front Final Gear Case Lower Bolts and Nuts 11 12 FINAL DRIVE Front Final Gear Case KAF400 A C e Remove Gear Case Breather Hose A e Move the front final gear case B toward the front C and remove the case from yoke D of the propeller shaft Front Final Gear Case Installation e Insert the pinion gear shaft A of the gear case in the yoke B and put the gear case on the frame Rou
160. er and lower level lines A x 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 1 18000851 Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrolyte Specific Gravity A WARNING Electrolyte contains sulfuric acid which is harmful to skin eyes and clothing Wear eye protection and rubber gloves If spillage occurs on body or clothing rinse at once with water for at least 15 minutes e Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer ORead the level of the electrolyte A on the floating scale Specific Gravity Standard 1 270 20 C 68 F the specific gravity is below 1 200 charge 70 the battery needs to be charged NOTE OThe specific gravity of the electrolyte varies with changes in temperature so the specific gravity reading must be corrected for the temperature of the electrolyte OCelsius Add 0 007 points to reading for each 10 C above 20 C or subtract 0 007 points for each 10 C be low 20 C OFahrenheit Add 0 004 points to reading for each 10 F above 68 F or subtract 0 004 points for each 10 F be low 68 F x If the specific gravity of any of the cells is more than 0 050 away from any other
161. ering Knuckle Installation e Check the joint boot A is not torn worn deteriorated or is leaking grease x If it is found replace the knuckle e Using a cleaning fluid clean off any oil or dirt on the taper surface B of the knuckle joint and dry it with a clean cloth e Using a cleaning fluid clean off any oil or dirt on the taper surface C in the front suspension arm D and dry it with a clean cloth e Grease Front Suspension Arm Joint Boot Sealing Surfaces A B Good C Bad e Tighten Torque Strut Clamp Nuts 98 10 kgf m 72 ft Ib Front Suspension Arm Joint Nut 78 8 0 kgf m 58 ft Ib Tie rod End Nuts 34 N m 3 5 kgf m 25 ft lb e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the clamp bolt or joint tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slit goes past the nearest hole e Bend the cotter pin A over the nut B e Install the removed parts e Check Toe in of Front Wheels see Wheels Tires chapter HJ07007BS1 GJ04109BS1 C STEERING 14 11 Steering Knuckles Knuckle Bearing Removal e Remove Steering Knuckle see Steering Knuckle Removal Circlip A Special Tool Inside Circlip Pliers B 57001 143 e Drive the bearing A out using a suitable bearing driver in
162. esses C in the head light e Install Spring A and Adjusting Screw e Install the nut B so that the flat side faces upward e Insert the headlight lead A in the grommet B and install itin the headlight body 16 46 ELECTRICAL SYSTEM Lighting System e Install the removed parts Nuts A Dampers B Collars C Washers D Bolts E Collar F Screws G 1913001852 C Tail Brake Light Replacement e Remove Screws A Tail Brake Light Lens B e Push the bulb A in turn it counterclockwise and pull it out of the socket NOTICE Do not use bulbs rated for greater wattage than the specified value e Insert the new bulb by aligning the pins A with the grooves in the walls of the socket e Push the bulb in turn it clockwise and release it It should be lock in position e Install Tail Brake Light Lens Screws OBe careful not to overtighten the lens mounting screws ELECTRICAL SYSTEM 16 47 Lighting System Light Switch Bulb Replacement e Remove Front Cargo Compartment see Frame chapter e Turn the socket A counterclockwise and pull it with the bulb e Pull the bulb A out of the socket Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Insert the new bulb in the socket e Align the projections B of the socket with the recesses 10138018 P C in the
163. ey spring broken or weak Converter engagement speed too high Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly in stalled too loose Shifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Driven pulley spring incorrect installed too tight Driven pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift arm bent or seized Gear stuck on the shaft Shift cable maladjusted Shift cable lubrication inadequate Shift cable damaged Jumps out of gear Shifter groove worn Gear dogs worn Shift arm positioning bolt spring weak or broken Shift block worn 17 4 APPENDIX Troubleshooting Guide Transmission shaft and or gear splines worn Shift cable maladjusted Overshifts Shift arm positioning bolt spring weak or broken Shift cable maladjusted Abnormal Engine Noise Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin holes w
164. f the outer rotor If the measurement exceed the service limit replace the rotors as a set Inner and Outer Rotor Clearance Standard Less than 0 14 mm 0 006 in Service Limit 0 20 mm 0 00787 in e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor Outer Rotor Outside Diameter Standard 40 53 40 56 mm 1 5957 1 5968 in Service Limit 40 47 mm 1 5933 in e Measure the thickness B of the outer rotor with a mi crometer at several points x If the rotor thickness is less than the service limit replace both the inner and outer rotor Outer Rotor Thickness Standard 9 98 10 00 mm 0 3929 0 3937 in Service Limit 9 94 mm 0 3913 in KF07001BS1 C ENGINE LUBRICATION SYSTEM 6 9 Oil Pump Relief Valve e Measure the inside diameter A of the pump housing with an inside micrometer at several points xIf the inside diameter is more than the service limit re place the crankcase cover Pump Housing Inside Diameter Standard 40 680 40 701 mm 1 6016 1 6024 in Service Limit 40 801 mm 1 6063 in e Measure the depth B of the pump housing with a depth micrometer at several points xIf any of measurement is more than the service limit re place the crankcase cover Pump Housing Depth Standard 10 03 10 08 mm 0 3949 0
165. fied range the deflection is normal x If the belt deflection is not within the specified range first measure the drive belt width see Drive Belt Inspection Adjust the deflection by adding or removing shims under the deflection bolts e When adjusting the deflection less is better than more Less deflection will maintain better performance for more time as the belt width decreases by normal wear which causes the deflection to increase with usage Even if the deflection is adjusted when the belt deflection is greater than the service limit replace the drive belt IF05001BS1 1 08000851 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Converter Drive Belt Deflection Adjustment e Inspect the drive belt deflection see Drive Belt Deflection Inspection xIf the belt deflection is more than 44 mm 1 73 in re move the deflection bolts A and replace the shims B To decrease the deflection increase the thickness of the shims OThe rule of thumb is 0 1 mm 0 004 in change in shim thickness equals about 1 4 mm 0 055 in change in belt deflection x If the belt deflection is less than 22 mm 0 87 in remove the deflection bolts and replace the shims To increase the deflection decrease the thickness of the shims OThe rule of thumb is 0 1 mm 0 004 in change in shim thickness equals about 1 6 mm 0 063 in change in belt deflection shims Part No Thickness 92
166. ft lb 22 400 r min rpm 27 9 Nm 2 8 kgf m 20 6 ft lb 22 200 r min rpm Carburetor NIKKI 6C1026 Electric starter Magneto and Transistor 20 Constant 1 10 GENERAL INFORMATION General Specifications KAF400 A1 A6F A9F C1 Items C6F C9F KAF400 B1 B6F B9F Spark Plug 5 Valve Timing Inlet Open 19 BTDC Close 61 ABDC Duration 260 Exhaust Open 58 BBDC Close 22 ATDC Duration 260 Lubrication System Forced lubrication wet sump Engine Oil Grade API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE10W 40 Capacity 1 4 L 1 5 US qt Drive Train Primary Reduction System Type Belt drive torque converter Reduction ratio 3 653 0 794 Transmission Gear Ratio Forward High 2 916 35 24 x 36 18 Low 4 315 41 19 x 36 18 Reverse Low 3 750 30 16 x 36 18 Final Drive System Type Gear 4WD 2WD Gear 2WD Reduction Ratio Front 3 851 16 18 x 39 9 Rear 4 000 64 16 Overall Drive Ratio Forward High 9 263 Low 13 706 Reverse Low 11 910 Front Final Gear Case Oil A C Type API GL 5 SAE140 or GL 6 SAE90 Hypoid gear oil for LSD Capacity 0 35 L 0 37 US qt Transmission Oil Type API GL 5 Hypoid gear oil SAE90 above 5 C 41 F or SAE80 below 5 C 41 F Capacity 2 4 L 2 5 US qt 2 2 L 2 3 US at GENERAL INFORMATION 1 11 General Specifications KAF400 A1 A6F A9F C1 C6F C9F KAF400 B1
167. g kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Fuel Hoses Replacement e Tilt up the cargo bed and seat e Slide out the clamps A e Remove the hoses B see Exploded View in Fuel System chapter e When installing route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed e Fit the fuel hose A onto the fitting fully and install the plate clamp B beyond the raised rib C 1 2 mm 0 0039 0 0078 D OThe hose end must reach the filler E or be as near as possible to the step F Idle Speed Inspection e Start the engine and warm it up thoroughly e Tilt up the cargo bed e Check the idle speed with a suitable tachometer Idle Speed Standard 1 100 1 250 r min rpm x If the idle speed is out of the specified range adjust it d 6505006851 6505005851 C 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment e Start the engine and warm it up thoroughly e Tilt up the cargo bed e Remove Guard Plate see Frame chapter Link Plate Cover A e Loosen the accel lever stopper
168. g point and can cause the brake to be ineffective or fail and it may cause rubber parts to deterioate resulting in an accident causing injury or death Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake Don t leave the reser voir cap off for any length of time to avoid moisture contamination of the fluid Don t add or change the fluid in the rain or when a strong wind is blowing If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately Brake Fluid Level Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brakes in the Periodic Maintenance chapter Brake Line Air Bleeding e Tilt up the front cargo hood e Remove Rubber Cap Brake Fluid Reservoir Cap e Level the reservoir A and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time dur ing bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e With the reservoir cap off slowly p
169. he carburetor 3 20 FUEL SYSTEM Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the throttle and choke shafts to check that the throttle and choke valves move smoothly Throttle Valve A Choke Valve B x If the valves do not more smoothly replace the damaged parts e Check the float A for cracks x If there any cracks replace the float NOTE OFloat height can not be adjusted e Check the tip A of the float valve needle B It should be smooth without any grooves scratches or tears x If the tip is damaged replace the valve needle Pilot Screw Setting Do not turn the pilot screw You may cause poor running at low engine speed Do not force or over tighten the pilot screw It could be damaged requir ing replacement FUEL SYSTEM 3 21 Carburetor OThe pilot screw A is set at the factory and should not be adjusted But if necessary set the pilot screw as follows e Remove Carburetor see Carburetor Removal e Punch a hole in the plug B and pry it out with an awl or other suitable tool e Turn in the pilot screw and count the number of turns until it seats fully but not tightly OBack out the same number of turns count
170. he drive pulley holder as shown Torque Drive Pulley Bolt 94 N m 9 6 kgf m 69 ft Ib NOTICE To avoid damage to the converter case bolts steel cover screws and fixed shave caused by overtight ening the drive pulley bolt eBe sure to clean oil off the tapered portion of the crankshaft and fixed shave eNever tighten the drive pulley bolt with an impact wrench Use a torque wrench e Remove the drive pulley holder e Tighten the two bolts A holding the drive pulley bolt B with a wrench Torque Drive Pulley Cover Bolts 23 N m 2 3 kgf m 17 ft lb 17204005851 C 5 14 CONVERTER SYSTEM Torque Converter e Set the slit A of duct to aligning mark B e Install Torque Converter Cover C Duct D Collar E Cover Bolts F 9 KAF400AAF BAF CAF Early Models e Tighten Torque Converter Cover Bolts 4 4 N m 0 45 kgf m 39 in Ib KAF400AAF BAF CAF Later Models e Apply a non permanent locking agent LOCTITE 243 to the threads of the converter cover bolts e Tighten Torque Converter Cover Bolts 6 0 0 61 kgf m 53 in Ib J IF04003BN3 C CONVERTER SYSTEM 5 15 Torque Converter Torque Converter Case Removal e Remove Drive Pulley Driven Pulley and Drive Belt see Torque Converter Removal Converter Case Front Bolts A and O rings Converter Case Rear Bolts B and Washers Dampers and Collars Torque Converter Case C Torque Converter Case
171. he outside diameter e While the band is held at the diameter above tap down the tangs A of the band Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it HK13004BS1 C A 12 ez 11078016 P 6114010151 11 48 FINAL DRIVE Axles Grease Seal Inspection e Visually inspect the grease seals Replace if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or been oth erwise damage 12 1 Brakes Table of Contents Exploded E 12 2 EE 12 6 Special TOONS 12 7 Brake tote ss ele 12 8 Brake Fluid 1 1 41 1 0 4 0 1 tnnt tentes 12 8 Brake Fluid Level Inspection 12 8 Brake Fluid Charge ree teet 12 8 Brake Line Air Bleeding WE 12 8 Brake Pedal
172. he remover set Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 A 57001 1216 Brake Drum Remover B 57001 1260 e Hold the brake drum remover and tighten the rotor puller e Remove Brake Drum Brake Drum Installation e Apply lithium grease NLGI Grade No 2 to the brake drum grease seal lips A and inside B of the drum as shown Grease Seal KAF400 A C models C Brake Drum D 1407001851 e Install Brake Drum e Mount the brake drum holder A securely on the drum studs with the wheel nuts Special Tool Brake Drum Holder 57001 1325 e For front brake drum using the brake drum pusher B and tighten it until the pusher stops Special Tool Brake Drum Pusher M18 x 1 5 57001 1261 e And then remove the pusher install the washer and axle nut e Tighten Torque Front Axle Nuts 147 N m 15 kgf m 108 ft Ib e For rear brake drum install the washer and axle nut e Tighten Torque Rear Axle Nuts 304 31 kgf m 224 ft Ib Brake Drum Wear e Refer to the Brakes in the Periodic Maintenance chapter 12 14 BRAKES Brake Panel Assemblies Brake Panel Assy Removal e Remove Brake Drum see Brake Drum Removal Breather Hose Brake Pipe Nipple A and Brake Pipe B Clip for Front Brake Panel e Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove for Rear Brake Panel
173. hock Absorber eene 13 6 Strut Front Shock Absorber Installation eese 13 6 Rear Shock Absorber Preload 13 7 Rear Shock Absorber 13 8 Rear Shock Absorber Installation 13 8 Rear Shock Absorber 13 8 Front SUSPENSION AIMS ox d eR Ep e tee ead 13 9 Front Suspension Arm 13 9 Front Suspension Arm Installation 13 10 Front Suspension Arm Inspection pp 13 10 SANTI CL Se tibetan wie 13 11 Swingarm Removal TR 13 11 e tee le unt EE 13 11 ene ere EE 13 12 Swingarm Joint Replacement 13 12 13 2 SUSPENSION Exploded View SUSPENSION 13 3 Exploded View Torque No Fastener Nem kgf m ftlb Remarks 1 Strut Mounting Nuts 49 5 0 36 2 Strut Clamp Nuts 98 10 72 3 Front Suspension Arm Pivot Bolts 88 9 0 65 4 Front Suspension Arm Joint Nuts 78 8 0 58 5 Swingarm Joint Nut 54 5 5 40 6 Swingarm Rod Bolts 50 5 1 37 7 shock Absorber Mounting Nuts 54 5 5 40 R Replacement Parts 13 4 SUSPENSION Specifications Item Standard Service Limit Rear Shock Absorbers Usable Range Spring preload setting position 3rd position 1 5 positions SUSPENSION 13 5 Special Tool Outside
174. ice Limit 0 4 mm 0 016 in e Measure the armature winding resistance OSet the multimeter selector switch to the R x 1 position and check the resistance between each segment and all the others x If the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close to 0 O e Set the multimeter selector switch to the R x 1 position and measure the resistance between the commutator and the armature shaft lf the resistance is less than infinite the armature is shorted Commutator to Shaft Resistance e Test the armature winding for shorts OPlace the armature on a growler A OHold a thin metal strip e g hack saw blade on top of the armature OTurn on the growler and rotate the armature one complete turn xIf the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced GP11060781 KH09014BS1 C 090158 5 16 40 ELECTRICAL SYSTEM Electric Starter System Yoke Assembly Inspection e Setthe multimeter selector switch to the R x 1 position and measure the resistance between the positive brushes and stator motor yoke If the resistance is less than infinite the positive brush is shorted to ground Replace the yoke assembly Positive Brush to Ground Resistance e Set the multimeter selector switch to the R x 1 Q posi
175. ide the adjuster B until the proper amount of throttle pedal free play is obtained e Tighten the mounting nuts securely e Start the engine e With the transmission in neutral operate the throttle pedal a few times to make sure that the idle speed does not change x If the idle speed does change the throttle cable may be improperly adjusted incorrectly routed or it may be dam aged Correct any of these conditions before operation AA WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions NOTE Olf the throttle pedal free play cannot be adjusted by us ing the adjuster at the cable lower end use the cable adjuster A at the cable upper end Do not forget to se curely tighten the adjuster mounting nuts B PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Fuel Hoses And Connections Inspection e Lift up the cargo bed and seat e Check the fuel hoses and fittings for deterioration cracks and signs of leakage Replace the fuel hose if any fraying leak A cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are installed correctly e When installing route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hoses avoid sharp bendin
176. ides of the tire are parallel with the rim flanges B x If the bead lines and the rim flanges are not parallel de flate the tire lubricate the sealing surfaces again and re inflate the tire e After the beads are properly seated check for air leaks OApply a soap and water solution around the tire bead and check for bubbles e Check the tire pressure using an air pressure gauge A NOTE OKawasaki provides the air pressure gauge P N 52005 1031 as the owner s tool Tire Air Pressure when cold Front 47 kPa 0 47 kgf cm 7 psi Rear KAF400 A C 97 kPa 0 97 kgf cm 14 psi KAF400 B 110 kPa 1 1 kgf cm 16 psi e Install the wheel see Wheel Installation e Wipe off the soap and water solution or water on the tire and dry the tire before operation AA WARNING Water or soap solution on the tire bead can cause tire separation and an accident resulting in serious injury or death Do not operate the vehicle until any water or soap solution applied to the bead has com pletely dried WARNING Operating with unequally or improperly pressurized tires can adversely affect steering or handling In flate both front tires to the same pressure and both rear tires to the same pressure Tire Wear Inspection e Refer to the Wheels Tires in the Periodic Maintenance chapter FINAL DRIVE 11 1 Final Drive Table of Contents Exploded View KAF400 A C 11 2 Driven Bevel Gea
177. ifications Item Standard Service Limit Engine Oil and Oil Filter Engine Oil Type API SG SH SJ SL or SM with JASO MA MAT MA2 Viscosity SAE10W 40 Capacity 1 1 3 L 1 37 US qt when filter is removed Oil Level BetweenLand H lines on dipstick Oil Pump and Relief Valve Inner Rotor Outer Rotor Clearance Outer Rotor Outside Diameter Outer Rotor Thickness Pump Housing Inside Diameter Pump Housing Depth Pump Shaft Outside Diameter Pump Shaft Bearing Inside Diameter Relief Valve Spring Free Length Less than 0 14 mm 0 006 in 40 53 40 56 mm 1 5957 1 5968 in 9 98 10 00 mm 0 3929 0 3937 in 40 680 40 701 mm 1 6016 1 6024 in 10 03 10 08 mm 0 3949 0 3968 in 12 695 12 715 mm 0 4998 0 5006 in 12 735 12 750 mm 0 5014 0 5020 in 16 5 mm 0 6496 in 0 20 mm 0 0079 in 40 47 mm 1 5933 in 9 94 mm 0 3913 in 40 801 mm 1 6063 in 10 16 mm 0 4000 in 12 645 mm 0 4978 in 12 811 mm 0 5044 in 15 7 mm 0 618 in ENGINE LUBRICATION SYSTEM 6 5 Engine Oil Flow Chart 011 Flow q Oil Pump Rocker Arms Oil Filter Camshaft Relief Valve Crankshaft Oil Screen 1 2 3 4 5 6 7 6 6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accele
178. igher than normal charging rates also cause the plates to shed active material Deposits will accu mulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 113 F during charging reduce the charging rate to lower the temperature and increase charg ing time proportionately e Remove Battery see Battery Removal 16 20 ELECTRICAL SYSTEM Battery e Connect a charger to the battery BEFORE plugging it in or turning it on e Set the charging rate and time according to the battery condition previously determined using the Battery Charg ing Rate Time Table e Check the electrolyte level after charging e Turn the charger off or unplug it then disconnect it from the battery e Check battery condition x If the battery condition indicates that it is not fully charged additional charging time is necessary Battery Charging Rate Time Table Es 1 27 elt Fully Gharged 1 24 BE 2 lt 1 20 1 16 1 140 KE See Ee SSS 5 1 12 Sample ei VO e d a mE ARI 1127149 1 7 1 08009 n ntt oie siesta l Hours 7 1 7 Totally discharged 7 77 7 E UE lioet Nee votes LO REN M ce T T T TPT i T T d 1 Eero npe at 1A charge rate 1 5 10 15 20 21 at 2A charge rate 1 3 5 7 10 5 at charge rate T 1 l at 4A charge rate 1 1 i ER Hours of Gharging
179. il filler hole Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely 1604001851 e Install the oil level gauge securely Engine Oil Change e Refer to the Engine Oil Change section in the Periodic Maintenance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement section in the Periodic Maintenance chapter 6 8 ENGINE LUBRICATION SYSTEM Oil Pump Relief Valve Oil Pump Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankshaft chapter e Remove the circlip A and oil pump assembly pump cover plate inner rotor outer rotor Oil Pump Installation e Fill the rotor housing with engine oil for initial lubrication e Install the pump assembly and circlip in the crankcase COVer Olnstall the circlip A with the tapered side out B as shown in figure Oil Pump Inspection e Remove the oil pump see Oil Pump Removal in this chapter e Visually inspect the pump gear outer and inner rotor and cover plate x If there is any damage or uneven wear replace them OCheck the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point o
180. in 19 08 mm 0 751 in 19 06 mm 0 750 in 81 79 mm 3 220 in 82 10 mm 3 232 in 0 05 mm 0 0020 in 0 2 100 mm 0 008 3 937 in 0 2 100 mm 0 008 3 937 in Specifications ENGINE BOTTOM END 8 5 Item Standard Service Limit Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankshaft Main Journal Diameter Crankcase Side Crankshaft Main Bearing Inside Diameter Crankcase Side Balancer Shaft Balancer Shaft Journal Diameter Balancer Shaft Bearing Inside Diameter Crankcase Side Crankcase Cover Side 27 4 27 7 mm 1 079 1 091 in 28 0 28 2 mm 1 102 1 110 in 43 004 43 015 mm 1 6931 1 6935 in 42 957 42 970 mm 1 6912 1 6917 in TIR 0 02 mm 0 0008 in or less 34 955 34 980 mm 1 3762 1 3772 in 35 002 35 015 mm 1 3780 1 3785 in 31 959 31 975 mm 1 2582 1 2589 in 32 000 32 016 mm 1 2598 1 2605 in 32 000 32 016 mm 1 2598 1 2605 in 27 0 mm 1 063 in 28 4 mm 1 112 in 43 04 mm 1 694 in 42 94 mm 1 691 in TIR 0 05 mm 0 002 in 34 93 mm 1 375 in 35 05 mm 1 380 in 31 935 mm 1 257 in 32 06 mm 1 262 in 32 06 mm 1 262 in 8 6 ENGINE BOTTOM END Special Tools Piston Ring Compressor Grip 57001 1095 7571095ST C Bearing Driver Set 57001 1129 7571129ST C
181. in the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound A Lapper B Valve Seat C Valve e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment GE15012081 ENGINE TOP END 4 15 Valves START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Tool small 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Lap Valve Tools Valve lapper grinding compound Purpose perfectly match valve and seat area check valve head for damage FINISHED 4 16 ENGINE TOP END Valves Valve Spring Free Length e Measure the valve spring A free length x If the free length is less than the service limit replace the valve spring with a new one
182. ing Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Non Permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent Do not apply them excessively Exces sive application can clog oil passages and cause serious damage 68020128 5 68020138 68020148 2 68020158 68020168 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be r pressed into place apply small amount of oil to the con
183. ions as shown D Arrow Mark x If the clearance is not within the specified range adjust it according to following chart Present Shoes Clearance Measurement Part Number Thickness 7 2 mm 49048 1087 0 283 in 7 3 up to 0 05 mm 0 0020 in 49048 1088 0 287 in 7 4 mm 49048 1089 0 291 in over 0 05 to 0 20 mm no change over 0 0020 to 0 0079 in 49048 1090 7 5 mm standard clearance 0 295 in 7 6 mm 49048 1091 0 299 in 7 7 mm 49048 1092 0 303 in 7 8 mm over 0 20 mm 0 0079 in 49048 1093 0 307 in 7 9 49048 1094 0 311 in 8 0 mm 49048 1095 0 315 in IF06014BS2 C IF06014BS2 C 5 22 CONVERTER SYSTEM Drive Pulley e Check that the movable sheave A moves smoothly after the shoe side clearance adjustment OThe movable sheave must move freely towards the fixed sheave B x If the movable sheave does not move smoothly readjust the shoe side clearance 1706015851 Bushing Installation e Press the cover bushing A into the cover B using the special tool so that the end of bushing is flush with the shoulder C in the hole Special Tool Bearing Driver Set 57001 1129 IF08016BS1 e Press the sheave bushing A into the movable sheave B using the special tool so that the end of bushing is flush with the shoulder C in the hole Special Tool Bearing Driver Set 57001 1129 D
184. ir Bleeding e Be sure to check the brake system for good braking power no brake drag and no fluid leakage WARNING After servicing it takes several applications of the brake pedal before the brake shoes contact the drum which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum e Inspect and if necessary adjust Parking Brake Lever Inspection see Parking Brake Lever Inspection in the Periodic Maintenance chapter Wheel Cylinder Removal Installation e Refer to Brake Wheel Cylinder Assembly Replacement in the Periodic Maintenance chapter Wheel Cylinder Assembly e Before assembly clean all parts including the wheel cylin der 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 al cohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline motor oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventu ally deteriorate the rubber used in the brake Wheel Cylinder Inspection e Remove the wheel cylinder see Brake Wheel Cylinder Assembly Replacement in the Periodic Maintenance chapter
185. ircuit BR BK Y BK BK W G W R a W G Be 1 Ignition Switch 2 Oil Temperature Warning Indicator Control Unit 3 Oil Temperature Sensor 4 Oil Temperature Warning Indicator Light 5 30 A Fuse 6 Battery W R W G SCHO x SE 1015005882 C Switches ELECTRICAL SYSTEM 16 51 Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the ignition switch light switch brake light switch and parking brake light switch refer to tables in the Wiring Diagram xIf the switch has an open or short repair it or replace it with a new one Neutral Switch Connections Neutral Switch Connections Color SW Terminal Ground When transmission is in neutral When transmission is not in neutral Reverse Light Switch Connections Europe Model Reverse Light Switch Connections Color SW Terminal Ground When transmission is in reverse When transmission is not in reverse Horn Switch Connections Europe Model Horn Button Connections Color BK W Ground Push Released 16 52 ELECTRICAL SYSTEM Fuses Fuse Removal e Remove 30 A Fuse Case A 10 A Fuse Case B e Open the fuse case and remove the fuse Fuse Installation x If a fuse fails during operation inspect the electrical sys tem to de
186. iston pin Piston Pin Outside Diameter Standard 18 995 19 000 mm 0 7478 0 7480 in Service Limit 18 96 mm 0 746 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge If the inside diameter is more than the service limit re place the piston Piston Pin Hole Inside Diameter Standard 19 004 19 015 mm 0 7482 0 7486 in Service Limit 19 08 mm 0 751 in e Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge If the inside diameter is more than the service limit re place the connecting rod Connecting Rod Small End Inside Diameter Standard 19 010 19 021 mm 0 7484 0 7489 in Service Limit 19 06 mm 0 750 in Z 2 2 KE06040BS1 C KE06042BS1 C 8 16 ENGINE BOTTOM END Cylinders and Pistons Piston Diameter e Measure the outside diameter A of the piston 18 mm 0 71 in up B from the bottom of the piston at a right angle to the direction of the piston pin hole the measurement is less than the service limit replace the piston Piston Diameter Standard 81 935 81 955 mm 3 2258 3 2266 in Service Limit 81 79 mm 3 220 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a dial bore gauge to measure front to back and side t
187. ith Cable Lubricant Throttle Cable Differential Shift Cable 2WD AWD Shift Cable KAF400 A C e Lubricate the cables by seeping the oil between the ca ble and housing OThe cable may be lubricated by using a pressure cable lubricator with an aerosol cable lubricant Cables Lubricate with Motor Oil Parking Brake Cables 6604011451 e With the cable disconnect at both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable gt is frayed B or if the cable housing is kinked C replace the cable e 6004020281 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts Nuts and Fasteners Tightness Inspection e Checkthe tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OCheck the engine fastener tightness when the engine is cold at room temperature x If there are loose fasteners first loosen by 1 2 turn then retorque them to the specified torque following the speci fied tightening sequence Refer to the appropriate chap ter for torque specifications If torque specifications are not in the appropriate chapter see the basic torque table see Torque and Locking Agent in this chapter x If cotter pins are damaged or removed replace them with new ones Nut Bolt and Fasteners to be checked Engine Engine Mounting Bolts Exhaust Pipe Hol
188. k air vent obstructed Fuel pump trouble Governor link mechanism malfunctioning Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other Engine oil viscosity too high Front final gear case oil viscosity to high KAF400 A C Drive train trouble Brake dragging Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap shorted or not in good con tact Spark plug incorrect Ignition coil trouble Fuel air mixture incorrect Choke valve stuck close Main jet clogged or wrong size APPENDIX 17 3 Troubleshooting Guide Fuel level too high or too low Air cleaner clogged poorly sealed or miss ing Water or foreign matter in fuel Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Governor link mechanism malfunctioning Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly val
189. k plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent IC igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and IC igniter Spark Plug Removal e Remove Guard Plate see Frame chapter Spark Plug Cap A e Remove the spark plug using the plug wrench B Special Tool Spark Plug Wrench Hex 21 57001 110 Spark Plug Installation e Tighten Torque Spark Plug 22 N m 2 2 kgf m 16 ft Ib e Fit the spark plug cap securely e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Spark Plug Cleaning Inspection e Refer to the Spark Plug Cleaning Inspection in the Peri odic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter Ignition Coil Removal e Remove Alternator Cover see Alternator Rotor and Stator Re moval Ignition Coil Lead Connector A disconnect Ignition Coil Bolts B Ignition Coil C ELECTRICAL SYSTEM 16 31 Ignition System Ignition Coil Installation e Install Ignition Coil A Ignition Coil Bolts e While tightening the bolts adjust the air gap B between the leg of
190. kgf m 61 in Ib e Install the parts removed e Adjust Throttle Pedal Free Play Adjustment Choke Cable Free Play Adjustment Idle Speed Adjustment Carburetor Disassembly A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Carburetor see Carburetor Removal Float Chamber Mounting Bolt A and Gasket Float Chamber B 1Cc07001BS2 C Carburetor FUEL SYSTEM 3 17 e Remove Pin A Float B and Float Valve Needle e Remove Main Jet A e Remove Pilot Jet Plug A e Remove Pilot Jet A 3 18 FUEL SYSTEM Carburetor Carburetor Assembly e Replace the following parts with new ones Circlip A Cap B Dust Seal C Gaskets D e Apply a non permanent locking agent Choke Valve Screws E Throttle Valve Screws F e Tighten Torque Choke Valve Screws 0 90 0 09 kgf m 7 8 in Ib Throttle Valve Screws 0 90 0 09 kgf m 7 8 in Ib Pilot Jet 0 70 N m 0 07 kgf m 6 1 in Ib Pilot Jet Plug H 2 5 N m 0 25 kgf m 22 in Ib Main Jet I 2 0 N m 0 20 kgf m 17 in Ib Drain Screw J 2 0 N m 0 20 kgf m 17 in Ib Float Chamber 9 8 1 0 87 in Ib e Install Choke Valve L Springs M Anti Ta
191. l Drive Bevel Gear KAF400 A C see Final Drive chapter Drive Shaft Nut KAF400 B see Drive Shaft Nut Instal lation 9 28 TRANSMISSION Transmission and Shift Mechanism Transmission Cable Installation e Putthe shift lever A in the N Neutral position KAF400 1406004851 C e Putthe shift lever in the N Neutral position KAF400 B 1J06007BS1 C e Set the shift shaft A in the neutral position OAlign the punch mark B of the shift shaft with the boss C of the transmission case e Screw in the transmission cable end fully to the joint A of the shift shaft lever B e Pass the cable through the cable holder C e Install the shift shaft lever A so that the slit B of the lever aligns with the punch mark C of the shift shaft e Tighten the shift shaft lever bolt D Torque Shift Shaft Lever Bolt 14 1 4 kgf m 10 ft Ib Transmission and Shift Mechanism TRANSMISSION 9 29 e Push the cable A lightly rearward B to remove the cable free play e Tighten the nut C by hand and fit the nut to cable holder D to remove the cable free play e Tighten Nut E Nut F Transmission Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely within the cable housing x If the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable Shift Rod Bending e Visually inspect th
192. l e Remove Transmission Case split Transmission Shafts Governor Shaft Snap Pins A Governor Shaft B Washer thin C Washer thick D e Remove the governor assembly A with the sleeve B by prying the gear C with two suitable levers NOTICE Do not remove the governor assembly unless it is necessary Once it has been removed it must be replaced e Remove the washer Governor Assembly Installation e Apply molybdenum disulfide grease to the governor shaft e Fitthe sleeve into the governor assembly and install them as a set NOTE OThe sleeve and the governor assembly cannot be in stalled separately OPush the set onto the shaft until the step fits into the groove securely Sleeve A Governor Assembly B Step C Washer D Groove E Governor Shaft F 32 mm 1 26 in G e Check that the gear turns freely and the weights H move smoothly Governor Assembly Inspection e Visually check the governor assembly A for wear and damage x If any part is worn or damaged replace the assembly 1605002851 C Choke Cable FUEL SYSTEM 3 13 Choke Knob Free Play Inspection e Check that the choke knob returns properly and that the inner cable slides smoothly e Remove Guard Plate see Frame chapter e Push in the choke knob all the way e Check the choke cable free play A ODetermine the amount of free play at the choke knob Pull the choke knob until the starter lev
193. l alcohol or ethyl al cohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline motor oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventu ally deteriorate the rubber used in the brake OPush the piston assembly in all the way with a screwdriver and install the piston stop bolt Use a new aluminum washer OTighten Torque Piston Stop Bolt 8 8 N m 0 90 kgf m 78 in Ib Reservoir Clamp Bolt 6 2 N m 0 63 kgf m 55 in Ib e Install the master cylinder see Master Cylinder Installa tion in the Brakes chapter 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Inspection e The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace it if any cracks B or bulges C are noticed e The metal pipe will rust if the plating is damaged Replace the pipe if it is rusted cracked especially check the fittings or if the plating is badly scratched see Brake Hose and Pipe Replacement in this section Brake Hose and Pipe Replacement e Remove Front Cargo Compartment see Frame chapter Left and Right Side Cover see Frame chapter Floor Center Panel see Frame chapter Wheels see Wheels Tires chapter e Drai
194. l rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has rough spots replace it Oil Seal Inspection e Visually inspect the oil seal Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged 6114010151 FINAL DRIVE 11 27 Bevel Gear Case KAF400 A C Driven Bevel Gear Removal e Remove Transmission Oil drain see Transmission Oil Change in the Periodic Maintenance chapter Left Rear Wheel see Wheels Tires chapter Rear Propeller Shaft see Propeller Shaft Removal Bolts A and Cable Bracket B 2WD AWD Shift Cable End C e Remove Bevel Gear Case Bolts A Bevel Gear Case B e Remove Driven Bevel Gear Assembly A Driven Bevel Gear Installation e Check and adjust the bevel gear backlash and tooth con tact when any of the backlash related parts are replaced see Bevel Gear Adjustment e Check to see that the bevel gear case dowel pins A are in place e Insert the shift shaft pin in the groove of the sifter and install the bevel gear case e Apply liquid gasket Bevel Gear Case Mating Surface A Sealant Liquid Gasket TB1216B 92104 1064 e Tighten Torque Bevel Gear Case Bolts 20 N
195. lean cloth into the torque converter cover duct to keep dirt out of the torque converter If dirt gets into the torque converter excessive wear and loss of driving power may result 5 10 CONVERTER SYSTEM Torque Converter Torque Converter Removal e Remove Right Rear Wheel see Wheels Tires chapter Right Rear Shock Absorber see Suspension chapter Right Side Cover see Frame chapter Cover Bolts A Torque Converter Cover B and Duct C e Remove the two bolts A holding the drive pulley bolt B with a wrench sure to remove the two bolts A in the positions shown Note the two bolts are not relative position the arrow mark C e Install the drive pulley holder A Special Tool Drive Pulley Holder 57001 1620 e Tighten the two bolts B Torque Drive Pulley Cover Bolts 23 N m 2 3 kgf m 17 ft Ib Be sure to install two bolts in the specified posi tions shown Otherwise the tapped holes will be damaged e Loosen the drive pulley bolt C holding the drive pulley with the drive pulley holder as shown e Remove Drive Pulley Bolt Two Washers Stepped Washer e Remove the drive pulley A from the crankshaft by screw ing the drive pulley puller bolt B clockwise while holding the drive pulley with the drive pulley holder C as shown Special Tool Drive Pulley Puller Bolt 57001 1429 CONVERTER SYSTEM 5 11 Torque Converter NOTE OBefore removing the drive belt observe
196. lement e Tighten Mounting Screw Clamp Screw Air Cleaner Element Cleaning e Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter FUEL SYSTEM 3 23 Air Cleaner Air Cleaner Housing Removal e Remove Air Cleaner Element see Air Cleaner Element Removal Air Cleaner Ducts A e Remove Fuel Pump Bracket Bolt A Air Cleaner Housing Bolts B Air Cleaner Housing C Air Cleaner Housing Installation e Tighten Torque Air Cleaner Housing Bolts 17 1 7 kgf m 12 ft lb Air Cleaner Housing Bolts KAF400ABF 5 5 Nm 0 56 kotm 48 in Ib Fuel Pump Bracket Bolt 5 4 N m 0 55 kgf m 48 in Ib e Install the air cleaner ducts and tighten the clamps Air Cleaner Housing Dust and or Water Installation If you see any dust and or water accumulated in the hous ing remove the drain cap A at the bottom of the air cleaner housing B and expel it C Clamp 1608000851 C 3 24 FUEL SYSTEM Fuel Pump Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Tilt up the Seat e Remove Fuel Hoses A Vacuum Hose B Fuel Pump Mounting Bolts C Fuel Pump D NOTE OFor KAF400ABF ACF BBF models
197. length C as sown C 0 9 1 3 mm 0 012 0 051 in ODoes not scratch the contact surface D of the oil seal e Apply molybdenum disulfide grease to the oil seal lip A and spline B of the bearing housing C e Install Spring D e Insert the front universal joint E into the bearing housing ORefer to Propeller Shafts Assembly in the Front Pro peller Shaft Installation for universal joint installation e Push the propeller shaft F forward fully and install the rear universal joint G on the bevel gear shaft H e Tighten Torque Yoke Stop Bolt I 8 8 N m 0 90 kgf m 78 in Ib Bearing Housing Bolts J 42 N m 4 2 31 ft Ib 1LO6002BS1 C 1196005842 C Propeller Shafts KAF400 A C FINAL DRIVE 11 39 Propeller Shaft Inspection e Visually inspect the splines of the propeller shafts x lf they are twisted badly worn or chipped replace the shafts Check that the universal joint works smoothly without rat tling or sticking x If it does not the bearings of the joint are damaged Re place the propeller shaft with a new one 11 40 FINAL DRIVE Axles Front Axle Removal KAF400 A C e Remove Front Suspension Arm and Steering Knuckle see Sus pension chapter Front Axle A OPull the axle straight Front Axle Installation KAF400 A C e Wipe the old grease off the splines A of the axle and cap oil seal B e Visually inspect the splines of
198. ll ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean parts If cleaning does not solve the problem replace the relief valve parts x If necessary put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat e Measure free length A of the spring with a vernier caliper x If the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Standard 16 5 mm 0 6496 in Service Limit 15 7 mm 0 618 in ENGINE LUBRICATION SYSTEM 6 11 Cil Screen Oil Screen Removal e Remove Engine Crankcase Cover see Engine Bottom End chapter Oil Screen Bolts A Pipe B e Push C the oil screen with thumbs and remove it Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert the oil screen A into slots B in the pipe C and install the pipe on the crankcase cover with the mounting bolts and spacers Oil Screen Cleaning Inspection e Clean the oil screen A with high flash point solvent and remove any particles stuck to it WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area
199. lve D e Remove the stem seals A NOTE Olt is not necessary to remove the stem seal unless it is being replaced OValve guide B is not replaceable do no remove it e Apply engine oil to the valve stems and install them e Check to see that the valve moves smoothly up and down in the guide e Install the spring and the valve retainer e Install the valve retainer while push down the valve re tainer with the thumbs e Install Cylinder Head see Cylinder Head Installation Rocker Arm Inspection e Clean and inspect the rocker arm where it touches the push rod and valve stem x If the contact points A are worn or damaged replace the rocker arm KE04003BS1 C Cylinder Head ENGINE TOP END 4 11 Cylinder Head Warp e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and the head xIf warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 03 mm 0 001 in 4 12 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection e Remove the valve e Check the valve seating
200. lybdenum disulfide grease O Apply oil R Replacement Parts 11 4 FINAL DRIVE Exploded View KAF400 A C Xx SD 29 11020458485 C FINAL DRIVE 11 5 Exploded View KAF400 A C Torque m Fastener Nem ftlb Remarks 6 2WDIAWD Shit 20 20 14 8 Bevel Gear Case Bolts 20 2 0 14 G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Liquid Gasket TB1216B 92104 1064 M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil The weight ratio of the mixture between engine oil and disulfide grease is 10 1 O Apply oil R Replacement Parts 11 6 FINAL DRIVE Exploded View KAF400 B FINAL DRIVE 11 7 Exploded View KAF400 B Torque Fast Remarks d eu Nm kgfm ftlb Bearing Holder 137 14 101 L Drive Shaft Nut 137 14 101 MO Rear Axle Bracket Bolts 40 4 1 Rear Axle Bracket Flange Bolts 49 5 0 G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 O Apply oil R Replacement Parts 11 8 FINAL DRIVE Specifications Item Standard Front Final Gear Case KAF400 A C Gear Case Oil Type Viscosity Capacity Oil Level LSD Clutch Torque Outside Friction Plate Thickness Inside Friction Plate Thickness Pinion Gear Preload Torque Bev
201. m 2 0 kgf m 14 ft Ib 11050128581 C 11 28 FINAL DRIVE Bevel Gear Case KAF400 A C Driven Bevel Gear Disassembly e Remove Driven Bevel Gear Assembly see Driven Bevel Gear Removal Snap Ring A Oil Seal B e Pry open the toothed washer tab A on the driven bevel gear slotted nut B with a small chisel e Unscrew the driven bevel gear slotted nut Special Tools Pinion Gear Holder m1 0 A 57001 1632 Socket Wrench B 57001 1283 e Remove Driven Bevel Gear Slotted Nut Washer Toothed Washer Ball Bearing C Shifter D e Remove Ball Bearing A Snap Ring B Collar C Driven Bevel Gear D Driven Bevel Gear Assembly e Install Ball Bearing A Toothed Washer B Washer C Driven Bevel Gear Slotted Nut D OApply molybdenum disulfide oil to the seating surface of the driven bevel gear slotted nut and tighten it Special Tools Pinion Gear Holder m1 0 57001 1632 Socket Wrench 57001 1283 Torque Driven Bevel Gear Slotted Nut 118 12 kgf m 87 ft lb 1105003851 C 1105004851 C Bevel Gear Case KAF400 A C FINAL DRIVE 11 29 e Bend the tab A of toothed washer over the slotted nut B e Install Shifter A Driven Bevel Gear B Collar C e Install Snap Ring A Special Tool Snap Ring Guide 20 B 57001 1633 Olnstall the snap ring on the snap ring guide OCover the snap ring guide A on the driven bevel gear shaft B
202. ments of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM United States Model only To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any way which results in an increase in noise level Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance an
203. meter A of the valve guide B x If the valve guide has worn past the service limit replace the cylinder head Valve Guide Inside Diameter Standard 7 000 7 015 mm 0 2756 0 2762 in Service Limit 7 08 mm 0 279 in Measuring Valve Guide Clearance Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B from the top of the head e Set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head upper surface e Move the stem back and forth C to measure valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve guide clearance be cause the measuring point is above the guide Valve Guide Clearance Wobble Method Standard Inlet 0 06 0 13 mm 0 0024 0 0051 in Exhaust 0 10 0 17 mm 0 0039 0 0067 in Service Limit Inlet 0 29 mm 0 011 in Exhaust 0 33 mm 0 013 in KE05020BS1 1E05002BS1 C 4 18 ENGINE TOP END Exhaust Pipe and Muffler Exhaust Pipe Removal e Remove Right Side Cover see Frame chapter Exhaust Pipe Clamp Nuts A e Remove Exhaust Pipe Clamp Bolts and Nuts A Exhaust Pipe B Muffler Removal e Remove Muffler Clamp Bol
204. moval e Remove Front Cargo Compartment see Frame chapter Cotter Pin A and Pin B Brake Hose Banjo Bolts C Brake Pipe Nipple D unscrew e Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove Master Cylinder Mounting Bolts E and Master Cylinder F Master Cylinder Installation e Use a new flat washer on each side of the brake hose fitting e Apply brake fluid to the brake pipe nipple threads e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Nipple 18 N m 1 8 kgf m 13 ft Ib e Bleed the brake line after master cylinder installation e Adjust the brake pedal play see Brake Pedal Play Inspec tion in the Periodic Maintenance chapter e Check that the brake line has proper fluid pressure and no fluid leakage Master Cylinder Disassembly Assembly e Refer to Brake Master Cylinder Cup and Dust Seal Re placement in the Periodic Maintenance chapter Brake Pedal and Master Cylinder BRAKES 12 11 Master Cylinder Inspection e Disassemble the master cylinder see Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter e Check that there are no scratches rust or pitting on the inside of the cylinder A and on the outside of the pistons B x the cylinder or piston shows any damage replace them e Inspect the primary cups
205. mper Plug N Idle Adjusting Screw O Throttle Valve P Collars Q Float Valve Needle R Pin S Float T 1607002853 FUEL SYSTEM 3 19 Carburetor Carburetor Cleaning WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the carburetor in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this in cludes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the carburetor Do not use compressed air on an assembled car buretor the float may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e When the parts are clean dry them with compressed air e Blow through the air and fuel passages with compressed air e Assemble t
206. mpletely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified e Tilt up the front cargo hood e Remove Rubber Cap A Front Cargo Compartment B PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Fill the reservoir to the upper level line A Upper Level Line MAX Lower Level Line MIN B e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake pedal has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately Brake Fluid Change e Tilt up the front cargo hood e Remove Rubber Cap Brake Fluid Reservoir Cap e Level the brake fluid reservoir A NOTE OThe fluid level must be checked several times during the fluid changing and replenished as necessary If the fluid in the reservoir runs completely out any time during fluid changing air bleeding must be done since air will have entered the line e Remove the wheel for extra clearance see Wheels Tires chapter e Remove the rubber cap from the bleed valve on the wheel cylinder e Connect a clear plastic hose A to the bleed valve at the wheel cylin
207. n leg and magnet Winding Resistance Spark Plug Standard Plug Spark Plug Gap 0 2 0 4 mm 0 0079 0 0157 in in the text BPRSES 0 7 0 8 mm 0 028 0 032 in Electric Starter System Starter Motor Carbon Brush Length Connector Groove Depth Commutator Outside Diameter Commutator Runout 10 mm 0 394 in 0 5 0 8 mm 0 020 0 031 in 28 mm 1 102 in 6 mm 0 236 in 0 2 mm 0 008 in 27 mm 1 063 in 0 4 mm 0 016 in Switches Brake Light Switch Timing Oil Temperature Sensor Resistance ON after 10 mm 0 39 in of pedal travel in the text ELECTRICAL SYSTEM 16 11 Special Tools Spark Plug Wrench Hex 21 Hand Tester 57001 110 57001 1394 875701105 7571394ST C 16 12 ELECTRICAL SYSTEM Parts Location Oil Temperature Warning Indicator Light A Parking Brake Indicator Light B Hour Meter C Ignition Switch D Accessory Connector Power Outlet E Light Switch F Horn Button G Europe Model Brake Light Switch A Starter Circuit Relay Brake A Frame Ground Terminal A Parking Brake Light Switch B Regulator Rectifier C Controller Unit D KAF400 A C Starter Circuit Relay Neutral E Battery F Spark Plug A ELECTRICAL SYSTEM 16 13 Parts Location Ignition Coil A Alternator B Oil Temperature Sensor C KAF400 A C Neutral Position Switch D Reverse Position Switch E Europe Model Engin
208. n the brake fluid e Remove Nipple A and Brake Pipe B Banjo Bolts C and Brake Hose D e Immediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove Nipples A Retainers B Brake Pipes C Brake Hose D e Remove Brake Pipe A PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures e Remove Wheels Nipple A Retainer Brake Pipe B e Use new copper washers A for each side of the hose fittings at the master cylinder e Tighten Torque Brake Hose Banjo Bolts B 25 N m 2 5 kgf m 18 ft lb 1514002851 C e Install the brake pipe A and tighten the nipple B Torque Brake Pipe Nipple 18 N m 1 8 kgf m 13 ft Ib e Fill the reservoir with new brake fluid see Brake Fluid Change e Check that the brake line has proper fluid pressure and no fluid leakage e Install the removed parts Brake Wheel Cylinder Assembly Replacement e Remove Brake Drum see Brake Drum Removal in the Brakes chapter e Remove the brake shoe spring A and brake shoes B individually OPush the shoe hold down springs C and twist the pins D to remove the shoes NOTE OWrap the brake shoes with a clean cloth to protect the linings from grease or dirt 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the brake pipe nipple A and plug the ni
209. n the fuel system are not vented into the atmosphere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or ele
210. n the tread or sidewalls indicate internal damage requiring tire replacement ORemove any foreign objects from the tread After re moval check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places xIf any of the measurements is less than the service limit replace the tire Tire Tread Depth Service Limit 3 mm 0 12 in Standard Tire KAF400 A C Front 24 x 9 00 10 DUNLOP KT869M Tubeless 24 x 9 00 10 DURO DI K968M Tubeless Rear 24 x 11 00 10 DUNLOP 869 Tubeless 24 x 11 00 10 DURO DI K968 Tubeless KAF400 B Front 22 x 9 00 10 DUNLOP KT901 Tubeless Rear 22 x 11 00 10 DUNLOP KT869 Tubeless Final Drive KAF400 A C models Front Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Park the vehicle so that it is level both side to side and front to rear e Remove Front Guard see Frame chapter Front Final Gear Case Skid Plate see Front Final Gear Case Oil Level Inspection in the Final Drive chapter e Place an oil pan beneath the front final gear case and remove the drain plug A A WARNING Oil on tires can cause loss of traction and an ac cident resulting in serious injury or death When draining or filling the final gear case do not spill oil the tire or rim Clean an
211. nance chapter Fuel Filter Installation e Refer to Fuel Filter Replacement in the Periodic Mainte nance chapter Fuel Filter Inspection e Visually inspect the fuel filter x lf the filter is clear with no signs of dirt or other contami nation it is OK and need not be replaced x If the filter is dark or looks dirty replace it Also check the rest of the fuel system for contamination Fuel Tank FUEL SYSTEM 3 27 Fuel Tank Removal WARNING Fuel is extremely flammable and can be explosive under certain conditions Turn the main switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Right Side Cover see Frame chapter Fuel Hose A disconnect Fuel Tank Bolt B Washer and Nut Fuel Tank C e Remove KAF400A9F ACF B9F BCF C9F CAF Models Clamps A Hose B Check Valve C Fuel Tank Installation e If the rubber dampers A were removed install them onto the frame or fuel tank with an adhesive e Replace the fuel tank nut with a new one e Install Damper A Collar B Washer C Fuel Tank Bolt D Nut E 1611000851 C 3 28 FUEL SYSTEM Fuel Tank e Install the check valve so thatthe arrow A faces fuel tank KAF400A9F ACF B9F BCF C9F CAF Models Black Color B Blue Color C e Install KAF400A9F ACF B9F BCF C9F CAF Models Hose
212. ncurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2004 Kawasaki Heavy Industries Ltd 10th Edition 0 Mar 11 2011 LIST OF ABBREVIATIONS A ampere s Ib pounds 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 F 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 COUNTRY AND AREA CODES CA Canada EUR Europe CAL US United States EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 exhaust emission 2 and evaporative emission 3 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air
213. nd replace repair as necessary Bad condition of piston ring and or Replace piston ring grooves Cylinder Head Removal e Remove Cargo Bed see Frame chapter Carburetor see Fuel System chapter Fan Housing see Alternator Removal in the Electrical System chapter Bolts A Tank B Engine Shroud C 4 8 ENGINE TOP END Cylinder Head e Remove Spark Plug Cap A Oil Level Gauge B Cylinder Head Cover Bolts C Cylinder Head Cover D e Position the crankshaft at TDC of the end of the compres sion stroke e Loosen Lock Screws A e Remove Valve Clearance Adjusting Nuts B Rocker Arm C Push Rods D e Remove Cylinder Head Bolts A Push Rod Guides B Cylinder Head C Cylinder Head Installation e Clean the mating surface of the cylinder head and the cylinder e Install the dowel pins A e Replace the gasket B with a new one e Install Cylinder Head Push Rod Guides A ENGINE TOP END 4 9 Cylinder Head e Tighten the cylinder head bolts following the tightening sequence as shown Torque Cylinder Head Bolts 37 N m 3 8 kgf m 27 16 e Apply engine oil to the push rods A and install them onto the tappet B OTo install the push rods A in the correct positions on the tappets B insert the push rod A so that the end of the push rod is sliding down along inside wall C of the crankcase and position the push rod end on to the tappet OCheck b
214. nes Brake Pedal Play Brake Drum Inside Diameter Brake Shoe Lining Thickness Parking Brake Lever Travel 2 5 mm 0 08 0 20 in 165 00 165 16 mm 6 4961 6 5023 in 4 mm 0 16 in 8 12 notches clicks 165 75 mm 6 526 in 1 mm 0 04 in Steering Steering Wheel Free Play 0 20 mm 0 0 79 in Electrical System Spark Plug Gap Battery Capacity Electrolyte Level Specific Gravity Switches Brake Light Switch Timing A KAF400 A Model B KAF400 B Model C KAF400 C Model 0 7 0 8 mm 0 028 0 032 in 12 V 14 Ah Between upper and lower level see text 1 270 20 68 F ON after 10 mm 0 39 in of pedal travel PERIODIC MAINTENANCE 2 11 Special Tools Inside Circlip Pliers Oil Filter Wrench 57001 143 57001 1249 7570143ST C 7571249ST C 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Pedal Free Play Inspection e Check that the throttle pedal moves smoothly from full open to close x If the throttle pedal does not return properly lubricate the throttle cable and link see Fuel System chapter e Check the throttle pedal free play A Throttle Pedal Free Play Standard 2 5 mm 0 08 0 20 in x If the free play is incorrect adjust the throttle cable Throttle Pedal Free Play Adjustment e Tilt up the cargo bed Loosen the adjuster mounting nuts A at the cable lower end e Sl
215. ness A OUse a micrometer to measure at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Standard Top Second 1 47 1 49 mm 0 0579 0 0587 in Service Limit Top Second 1 40 mm 0 0551 in NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston KE06038BS1 C 06010851 C Cylinders and Pistons ENGINE BOTTOM END 8 15 Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore OUse the piston to push it in to be sure it is square e Measure the gap A between the ends of the ring B with a thickness gauge x If the end gap of any ring is greater than the service limit replace the entire set of rings Piston Ring End Gap Standard Top 0 15 0 40 mm 0 0059 0 0157 in Second 0 23 0 48 mm 0 0091 0 0189 in Cil 0 25 0 75 mm 0 0098 0 0295 in Service Limit Top 0 7 mm 0 028 in Second 0 8 mm 0 031 in 1 0 mm 0 039 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the outside diameter of the piston pin with a mi crometer at several points xIf the outside diameter is less than service limit replace the p
216. ning e Refer to the Spark Arrester Cleaning in the Periodic Main tenance chapter CONVERTER SYSTEM 5 1 Converter System Table of Contents lA ee ET 5 2 Specifications TT 5 6 Special e e e ee t rec d HA 5 7 ClO ue 5 8 Air Cleaner Element Removal dtu eode s attt on 5 8 Air Cleaner Element Cleaning INSpection m 5 8 Air Cleaner Re EE 5 9 site Ee 5 10 Torque Converter Removal pp 5 10 Torque Converter Installation eese nnn 5 11 Torque Converter Case Removal 5 15 Torque Converter Case Installation eene 5 15 eot eege e E Un Qe d ee Reb inte dts Yea e uu ls 5 17 Prive Belt Tsernoval TEE SEENEN Ge E EE Ee ud dds Ce 5 17 Drive Belt Installation cierta aeter ea eb ior 5 17 Drive Belt InispectiOn tact deed tete e Tier bae Ha EA 5 17 Drive Belt Deflection Inspection pp 5 17 Drive Belt Deflection Adjustment Nb 5 17 Drive Pulley pe 5 18 Drive ee EE 5 18 Drive Pulley Bisassembolyo dE EES SE 5 18 Drive Pulley Inspection lad i p hn ene tede ce ir d Opa dede eae 5 19 Spider Shoe Side Clearance Adjustment 5 20 io aneBisriri jio me dere
217. nion gear and tighten the pinion gear nut to the specified torque Torque Pinion Gear Nut 156 16 kgf m 115 ft Ib e Do not install the oil seal and do not lock the bearing holder until the correct preload is obtained To start with choose a shim so that the bevel gears are just SNUG with NO play but also with NO preload An over preload on the gears could damage the gears e Measure the pinion gear preload The preload is the force or torque which is needed to start the gear shaft turning Torque Wrench A Special Tool Pinion Gear Holder m1 0 B 57001 1281 Front Final Bevel Gear Adjustment Procedure Preload the pinion gear Adjust gear backlash Adjust tooth contact pattern Assemble the final gear case completely 1L04012BS2 C Front Final Gear Case KAF400 A C FINAL DRIVE 11 21 x the preload is out of the specified range replace the ring gear shim s OTo increase preload decrease the size of the shim s To decrease preload increase the size of the shim s OChange the thickness a little at a time e Recheck the preload and readjust as necessary e Measure the preload using a torque wrench A Pinion Gear Preload Torque 0 5 0 05 kgf m 4 4 in Ib or less Special Tool Pinion Gear Holder m1 0 B 57001 1281 Backlash Adjustment e Check and adjust the gear backlash when any of the backlash related parts are replac
218. nkcase with a new one Balancer Shaft Bearing Inside Diameter Crankcase Standard 32 000 32 016 mm 1 2598 1 2605 in Service Limit 32 06 mm 1 262 in e Measure the inside diameter A of the balancer shaft bearing on the crankcase cover at several points x If inside diameter is more than the service limit replace the crankcase cover with a new one Balancer Shaft Bearing Inside Diameter Crankcase cover Standard 32 000 32 016 mm 1 2598 1 2605 in Service Limit 32 06 mm 1 262 in 8 22 BOTTOM END Breather The function of the breather is to create a negative pressure in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emission control system is used to prevent blow by gases from emitting in the air The blow by gases are drawn into the clean side of the air cleaner through the crankcase and the cylinder head and mixed with the clean air flow and subsequently comes into the combustion chamber through the carburetor Oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase and secondly separated from the gases in the breather chamber and then brought back to the crankcase prr ZI Fe Vo D RESTIN 1108000884 C ENG
219. nside diameter A of the drum at several points xIf any measurement is greater than the service limit re place the drum the drum is worn unevenly or scored lightly turn the drum on a brake drum lathe or replace it Do not turn the drum beyond the service limit Brake Drum Inside Diameter Standard 165 00 165 16 mm 6 4961 6 5023 in Service Limit 165 75 mm 6 526 in e Remove the brake drum for brake shoe inspection see Brake Drum Removal in the Brakes chapter e Measure the lining thickness at several points Brake Shoe Lining thickness Standard 4 mm 0 16 in Service Limit 1 mm 0 04 in If any measurement is less than the service limit replace both shoes as a set x If the lining thickness is greater than the service limit do the following before installing the shoes e File or sand down any high spots on the surface on the lining e Use a wire brush to remove any foreign particles from the lining e Wash off any oil or grease with an oilless solvent NOTICE Do not use asolvent which willleave an oily residue or the shoes will have to be replaced Parking Brake Lever Inspection e Check parking brake lever travel A by feeling clicks OPull the parking brake lever B upward slowly all the way Count the number of notches clicks during lever travel OThe vehicle should not roll while parked Parking Brake Lever Travel Standard 8 12 notches clicks e Release the parking
220. nstall Throttle Cable C e Temporarily tighten the throttle cable mounting nuts D View X E 1605010651 16005008852 C 3 10 FUEL SYSTEM Governor Link Mechanism e Screw in the accel lever stopper screw A until it keeps clearance by 1 mm 0 04 in B to the accel lever C at idle speed position Idle Speed about 1 100 1 250 r min rpm e Tighten the throttle cable mounting nuts D Oln this case do not extend the cable too much OThe idle screw E must contact to link lever F e Check that the governor arm G and accel lever pin H touch lightly when the throttle lever throttle pedal is fully opened e When the throttle pedal is fully pushed make sure that the carburetor throttle is in fully opened position x If it is not in fully opened position adjust the play of the throttle pedal and accel lever stopper screw to get the fully opened position of the carburetor throttle Adjust Throttle Pedal Free Play Adjustment Idle Speed Adjustment e Install the control panel assembly shroud with pop rivets 1C05006BS2 C FUEL SYSTEM 3 11 Governor Link Mechanism ug E17 EE p 1 Governor Arm 6 Collars 2 Link T Throttle Cable 3 Governor Spring 8 Washer 4 Bushing 9 Governor Arm Clamp Nut 5 Control Panel 3 12 FUEL SYSTEM Governor Link Mechanism Governor Assembly Remova
221. o inp Dein be dp den 15 29 Cooling Fan Guard Removal KAF400A9F AAF B9F BAF C9F 15 29 Cooling Fan Guard Removal ACF BBF BCE 15 30 Cooling Fan Guard Installation KAFA00A9F AAF B9F BAF C9F 15 30 Cooling Fan Guard Installation KAF400ABF ACF BBF 15 30 Guard Plate Removal 15 30 Guard Plate E diat ATAI 15 31 15 2 FRAME Exploded View FRAME 15 3 Exploded View 1 KAF400 A1 ABF B1 BBF C1 CAF Models AD Apply adhesive agent G Apply grease 15 4 FRAME Exploded View DETAIL A A A LOE on Wo ye IS P KY LL US Rey ES V Co 4 A A N 22 515 d 9 RAW S VA rans aval 4 Le A d FRAME 15 5 Exploded View SC LT Font Bar Mounting Bali Lower Ceo fp Front Bar Mounting Bolts Upper 32 Rear Bar Mounting Bolts L 20 mm 44 32 Rear Bar Mounting Bolts L 16 44 4 5 32 Seat Belt Mounting Bolts 34 3 5 25 Dampers 400 1 A9F B1 B9F C1 C9F Models KAF400 A1 B1 C1 Models KAFA00AGF A9F B6F 6 Models KAF400 A1 A9F B1 B9F C1 C9F Models KAF400AAF ACF BAF BCF CAF Models KAF400 A1 ABF B1 BBF C1 CAF Models AD Apply adhesive agent G Apply grease R Replacement Parts
222. o side at the points as shown in the figure x any of the cylinder bore measurements is greater than the service limit replace the crankcase 10 mm 0 39 in A 35 mm 1 38 in B Cylinder Inside Diameter Standard 81 97 81 99 mm 3 2272 3 2279 in Service Limit 82 10 mm 3 232 in Cylinder Bore Out Round Service Limit 0 05 mm 0 0020 in KE06043BS1 C KE06044BS1 C Crankshaft and Connecting Rods ENGINE BOTTOM END 8 17 Connecting Rod Removal e Refer to the Piston Removal for the connecting rod re moval Connecting Rod Installation e Refer to the Piston Installation for the connecting rod in stallation Crankshaft Removal e Drain the oil see Oil Change in the Periodic Maintenance chapter e Remove Alternator Rotor see Alternator Rotor and Stator Re moval in the Electrical System chapter Camshaft see Camshaft Tappet Removal Balancer Shaft see Balancer Shaft Removal Connecting Rod Cap see Piston Removal e Pull the crankshaft A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amount of grease to 6096 volume between the lips of the oil seal on the crankcase Press in the new oil seal 0 1 mm 0 0 04 in below the crankcase surface e Apply molybdenum disulfide g
223. od distance between the flange end B and the locknut C Tie rod Length distance between flange end and locknut Standard about 34 mm 1 34 in xIf the length is out of the specified adjust the tie rod length Loosen the locknut and turn the adjusting rod D to achieve the specified value NOTE OThe toe in will be near the specified range if the tie rod length is the specified value on the left and right e Tighten Torque Locknuts 44 N m 4 5 kgf m 32 16 e Check the toe in again e Test drive the vehicle 1K04000B 5 WHEELS TIRES 10 7 Wheels Rims Wheel Removal e Loosen the wheel nuts Do not remove e Support the vehicle on a stand or a jack so that the wheels are off the ground Special Tool Jack 57001 1238 e Remove Wheel Nuts Wheel s Wheel Installation e Check the tire rotation mark A on the tire and install the wheel accordingly NOTE OThe direction of the tire rotation B is shown by an arrow P on the tire sidewall lt ROTATION woe ee i e TTE HJ05019B e Position the wheel so that the valve stem A is toward the outside of the vehicle e Replace the wheel nuts with new ones e Tighten Torque Wheel Nuts 34 3 5 kgf m 25 ft lb OTighten the wheel nuts in a criss cross pattern 1K05B001 Wheel Rim Inspection e Examine both sides of the rim for dents A x lf the rim is dented
224. of the circlip is seen e Install the circlip B Special Tool Outside Circlip Pliers 57001 144 e Release the movable sheave slowly until it stops naturally Driven Pulley Installation Refer to the Torque Converter Installation CONVERTER SYSTEM 5 29 High Altitude Setting Information Specifications Altitude Drive Pulley Carburetor m ft Ramp Weights Main Jet 0 500 0 1 600 P No 39152 0011 STD Type C 112 P No 92063 7045 STD 500 1 500 1 600 4 900 P No 39152 0011 STD Type C 108 P No 92063 7044 1 500 2 500 4 900 8 200 P No 39152 0014 Type C155 105 P No 92063 7013 2 500 3 500 8 200 11 500 P No 39152 0014 Type C155 102 P No 92063 7014 3500 4500 11 500 14800 P No 39152 0014 Type C155 99 P No 92063 2458 C C155 Identification Marks e Refer to the Drive Pulley section in this chapter and Carburetor section in the Fuel System chapter for the parts replacement LUBRICATION SYSTEM 6 1 Engine Lubrication System Table of Contents E elle Lee WEE 6 2 eelere TEE 6 4 Engine Oil Flow EE 6 5 Engine Oil and EE 6 6 Oil Level Inspection p iude pe e sav td aa tete t be at a ots un 6 6 Engine Oil Change c 6 7 Oil Filter Repnlacement nn nnns enis 6 7 Oil Pump Relief Valve ir e dee Geass devia
225. on pp Tire Wear Inspection Final Drive KAF400 A C models Front Final Gear Case Oil Brake Fluid Level Inspection Brake Fluid Change Brake Pedal Play Inspection Brake Master Cylinder Cup and Dust Cover Replacement Brake Hose and Pipe Inspection Brake Hose and Pipe Replacement Brake Wheel Cylinder Assembly Replacement Brake Wear Parking Brake Lever Inspection Steering iere cea Steering Inspection Steering Joint Dust Boot Inspection pp IAIN UE Seat Belt Inspection Electrical System Battery Inspection Brake Light Switch Inspection General Lubrication Bolts Nuts and Fasteners Tightness Inspection 2 22 2 22 2 23 2 23 2 23 2 24 2 24 2 24 2 24 2 24 2 25 2 25 2 25 2 26 2 26 2 27 2 28 2 29 2 30 2 30 2 31 2 33 2 33 2 34 2 34 2 35 2 35 2 35 2 35 2 35 2 36 2 37 2 38 2 38 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected FRE
226. on chapter Special Tool Assembly Jig 57001 1631 e Tighten Torque Connecting Plate Bolts M10 55 5 6 kgf m 41 ft Ib Connecting Plate Bolts M8 28 N m 2 9 kgf m 21 ft Ib xIf the engine was removed refer to the Engine Re moval Installation chapter e Tighten the rear axle bracket flange bolts A while turning the axle bracket B toward the front side C Torque Rear Axle Bracket Flange Bolts 49 Nm 5 0 kgf m 36 ft Ib Rear Axle Bracket Bolts 40 4 1 kgf m 30 ft Ib e Remove the assembly jig Drive Shaft Nut Removal KAF400 B e Drain Transmission Oil see Transmission Oil Change in the Periodic Maintenance chapter e Remove Rear Wheels see Wheels Tires chapter Rear Brake Panels see Brakes chapter Rear Shock Absorbers see Suspension chapter Left Rear Axle Bracket and Axle Shaft see Transmission Case Removal 1J05003BS2 9 16 TRANSMISSION Transmission Case e Install Bevel Gear Holder A Special Tool Bevel Gear Holder 57001 1638 e Make a hole in the plug B with a chisel and pry the plug off NOTICE Do not insert the chisel deep in the plug This will damage the inside parts e Set the Differential Lock position e Remove Drive Shaft Nut A Washer Drive Shaft Nut Installation KAF400 B e Apply molybdenum disulfide oil to the threads and seating surface of the drive shaft nut A e Install Washer B Drive Shaft Nut
227. or Link Mechanism Control Panel Assembly Removal e Tilt up the cargo bed e Drill out the pop rivets A holding the control panel as sembly shroud B with a drill bit of the 5 mm 0 02 in diameter ODrill only until the rivet head comes off Do not drill through the hole e Remove Link A Governor Spring B Plate Connection Bolts C Control Panel Mounting Bolts D Control Panel Assembly E Control Panel Assembly Installation e Install Control Panel Assembly e Tighten Torque Control Panel Mounting Bolts 20 N m 2 0 kgf m 14 ft lb Plate Connection Bolts 8 8 N m 0 90 kgf m 78 in Ib e Insert the bushing A in the hole of the governor arm with click B 1605010451 6 e Insert the link A in the hole of the bushing B from upper side d UA UA 1605010551 Governor Link Mechanism FUEL SYSTEM 3 9 e Turn the bushing A counterclockwise until fitting on the link with click B e Hold the carburetor throttle full open A tighten the gov ernor arm nut B with pivot arm C and governor arm D are turned fully clockwise Short Straight Side E Olnsert a suitable rod in the hole on the pivot arm and turn the pivot arm Snap Pins G e Tighten Torque Governor Arm Nut 7 4 0 75 kgf m 65 in Ib NOTE ODo not transform the governor arm e Install Governor Spring A Return Spring B OHook the return spring from upside e I
228. orn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm push rod runout excessive Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure or damaged Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Transmission oil insufficient Final drive noise Bearing worn Gears worn or chipped Metal chips jammed in gear teeth Insufficient lubricant Bevel gears maladjusted KAF400 A C Worn LSD clutch friction plate KAF400 A C Worn LSD clutch spring KAF400 A C Universal joint damaged Abnormal Frame Noise Shock absorber noise Shock absorber damaged Brake noise Brake linings overworn or worn unevenly Drum worn unevenly or scored Brake spring s weak or broken Foreign matter in hub Brake not properly adjusted Other noise Bracket nuts bolts etc mounted or tightened Exhaus
229. oth inlet and exhaust push rods on each cylinder are lowest position on the cam lobes D If not turn the alternator rotor clockwise one turn and position the crank shaft at TDC of the compression stroke OBe sure the end of the push rods are correctly seated on the tappets 040178 52 C e Apply engine oil to the rocker arms e Install Rocker Arms Valve Clearance Adjusting Nuts e Check and adjust the valve clearance see Valve Clear ance Inspection in the Periodic Maintenance chapter e Install New Gasket Cylinder Head Cover e Tighten Torque Cylinder Head Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib Engine Shroud Bolts 5 9 N m 0 60 kgf m 52 in Ib 4 10 ENGINE TOP END Cylinder Head Push Rod Inspection e Place the rocker arm push rod in V blocks that are as far apart as possible and set a dial gauge A on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and the lowest dial readings is the amount of runout x If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit TIR 0 5 mm 0 02 in Valve Mechanism Removal Installation e Remove Cylinder Head see Cylinder Head Removal e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with thumbs and remove the collets e Remove the valve retainer spring C and va
230. ottle Pedal Free Play Inspection pp Throttle Pedal Free Play Adjustment Fuel Hoses And Connections Inspection sss Fuel Hoses Replacement Idle Speed Inspection Idle Speed Adjustment Fuel System Cleanliness Air Cleaner Element Cleaning Fuel Filter Replacement Evaporative Emission Control System Inspection California Model KAF400ABF ACF BBF US and Canada Models Engine Top End Valve Clearance Inspection Valve Clearance Adjustment Spark Arrester Cleaning Converter System Converter Air Cleaner Element Cleaning Inspection Converter Dust or Water Drain Cleaning uera pert en Converter Drive Belt Inspection Converter Drive Belt Deflection Inspection pp Converter Drive Belt Deflection Adjustment pp Converter Driven Pulley Shoe Inspection pp 2 20 2 21 2 21 Engine Lubrication System Engine Oil Change Oil Filter Replacement Transmission Transmission Change Electrical System Spark Plug Cleaning Inspection Spark Plug Gap Inspection Wheels Tires Wheels Nuts Tightness Inspecti
231. ound Clearance Seat Height Dry Weight Curb Weight Fuel Tank Capacity Cargo Bed L x W x H Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Ignition Timing 2 720 mm 107 09 in 1 335 mm 52 56 in 1 802 mm 70 94 in 1781 mm 70 12 in 1 779 mm 70 04 in 1 051 mm 41 38 999 mm 39 33 in 170 mm 6 69 in 155 mm 6 10 in 780 mm 30 71 in 768 mm 30 24 in A 442 kg 975 Ib AGF CAL 444 kg 978 Ib C 448 kg 988 Ib C6F CAL 450 kg 992 Ib KAF400A9F 458 kg 1 010 Ib KAF400B9F 429 kg 946 Ib 413 kg 911 Ib CAL 415 kg 915 Ib KAF400C9F US CN 464 kg 1 023 Ib CAL 466 kg 1 028 Ib 199 kg 439 Ib CAL 200 kg 441 Ib 179 kg 395 Ib CAL 180 kg 397 Ib A 259 kg 571 Ib AGF 261 kg 576 Ib A CAL 260 kg 573 Ib C 265 kg 584 Ib C6F 267 kg 589 Ib C CAL 266 kg 587 Ib 15 5 L 4 1 US gal 250 kg 551 Ib CAL 251 kg 553 Ib 1 044 x 900 x 245 mm 41 10 x 35 43 x 9 65 in Performance Minimum Turning Radius 3 3 m 10 83 ft 4 stroke OHV 2 valves 1 cylinder Positive air cooled 82 x 76 mm 3 23 x 2 99 in 401 cm 24 47 cu in 9 9 KW 13 5 PS 94 000 r min rpm 9 2 KW 12 5 PS 93 800 r min rpm 29 7 N m 3 0 kgf m 21 9
232. out the dipstick and check the oil level The oil level should be between the upper H and lower L level lines C x If the oil level is too high remove the excess oil using a syringe or some other suitable device through the oil filler opening f the oil level is too low add the necessary amount of oil through the oil filler opening Use the same type and make of oil that is already in the transmission NOTE Olf the transmission oil type and make are unknown use any brand of the specified oil to top up the level in pref erence to running the transmission with the oil level low Then at your earliest convenience change the oil com pletely Transmission Oil Change e Refer to the Transmission Oil Change in the Periodic Maintenance chapter TRANSMISSION 9 13 Transmission Case Transmission Case Removal e Drain Transmission Oil see Transmission Oil Change in the Periodic Maintenance chapter e Remove Cargo Bed see Frame chapter Propeller Shafts KAF400 A C see Final Drive chapter Bevel Gear Case KAF400 A C see Final Drive chapter Rear Wheels see Wheels Tires chapter Rear Brake Panels see Brakes chapter Rear Shock Absorbers See Suspension chapter Torque Converter Case see Converter System chapter e Remove ia Control Panel Assembly A see Fuel System chapter Transmission Shift Shaft Lever B and Holder C e Remove Differential Shift Cable Holder A
233. pacer N Spacers O Needle Bearings P Needle Bearing Q Washer R DI E D 9 Q0 D OW D Q0 de jum RAV umm A OOF o 5 1405004BW3 C TRANSMISSION 9 25 Transmission Case e Install KAF400 B Transmission Shaft A Drive Gear B Washer C Needle Bearings D Forward Gear E Spacer F Washer G Circlip H Shifter I Spacer J Needle Bearing K Reverse Driven Sprocket L Collar M Circlip N eR 00 0 9 1405008BW3 C 9 26 TRANSMISSION Transmission Case e Install the following parts on the drive shaft A Pin B Governor Drive Gear C Olnstall the governor drive gear so that the flat side D faces to the circlip e Install Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Install Shift Shaft A Transmission Shaft B Driven Shaft C Shift Rod D and Reverse Chain E e Insert the pin of the shift fork A into the shift shaft B e Install Pin C Install Differential Gear Assembly A Drive Shaft B e Check to see that the transmission case dowel pins C are in place TRANSMISSION 9 27 Transmission Case e Apply liquid Gasket Transmission Case Mating Surface A Sealant Liquid Gasket TB1216B 92104 1064 e Tighten Torque Transmission Case Bolts 8 8 N m 0 90 kgf m 78 1405000851 e Instal
234. paired or replaced or the replacement part will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow OElectrical Connectors Connectors A 8 06010151 C ELECTRICAL SYSTEM 16 15 Precautions Connectors B 8 06010251 C 16 16 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OMeasure the resistance between the ends of the leads x If the resistance is not 0 the lead is defective Replace the lead or the wiring harness if necessary 1907000851 C ELECTRICAL SYSTEM 16 17 Battery Battery Removal e Raise the seat e Disconnect the battery negative c
235. poid gear oil SAE90 above 5 C 41 F or SAE80 below 5 C 41 F Capacity 2 4 L 2 5 US qt 2 2 L 2 3 US qt Frame Type Steel tube Ladder Caster Rake Angle 8 Camber 17 40 mm 1 57 in 33 mm 1 30 in Tire Front 24 x 9 00 10 Tubeless 22 x 9 00 10 Tubeless Rear 24 x 11 00 10 Tubeless 22 x 11 00 10 Tubeless Rim Size Front 10 x 7 0 Rear 10 x 8 5 Steering Type Rack and pinion Suspension Front Type MacPherson strut Wheel travel 78 mm 3 07 in Rear Type Unit Swing Wheel travel 78 7 mm 3 10 in Brake Type Drum Hydraulic Drum Mechanical internal expansion Electrical Equipment Battery Headlight Type Bulb Brake Tail Light Reverse Light EUR Alternator Type Load Capacity Maximum Vehicle Load Including Occupants and Cargo Maximum Cargo Bed Load 12 V 14 Ah Semi sealed beam 12V35Wx2 12 V 21 5 W 12V 10W Single phase AC 17 A 12 5 V Rated output 420 kg 926 Ib 181 kg 400 Ib Specifications are subject to change without notice and may not apply to every country A KAF400A MULE 610 4 x 4 B KAF400B MULE 600 GENERAL INFORMATION 1 15 General Specifications C KAF400C MULE 610 4 x 4 Camouflage Surface Treated Model CA Canada Model CAL California Model EUR Europe Model US United States Model 1 16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol km x
236. pple Olmmediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Unscrew the mounting bolts B and take off the front brake wheel cylinder C e Replace the rear wheel cylinder with a new one e Apply liquid gasket to the hatched area A Sealant ThreeBond 1109 1 14001BS1 e Tighten Torque Wheel Cylinder Mounting Bolts 12 1 2 kgf m 106 in Ib Brake Pipe Nipple 18 N m 1 8 kgf m 13 ft lb e Install the removed parts see Brake Panel Assembly sec tion in the brakes chapter e Bleed the brake line after drum installation see Brake Line Air Bleeding in the Brakes chapter e Be sure to check the brake system for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake pedal before the brake shoes contact the drum which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum e Adjust Parking Brake Lever see Parking Brake Lever Inspec tion in this section PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Brake Wear Inspection e Remove the brake drum see Brake Drum Removal in the Brakes chapter e Measure the i
237. r Assembly 11 28 Exploded View KAF400 B 11 6 Drive Bevel Gear Removal 11 30 Specifications 11 8 Drive Bevel Gear Installation 11 31 Special Tools een 11 9 Bevel Gear Adjustment 11 31 Front Final Gear Case KAF400 A C 11 11 Bevel Gear Inspection 11 34 Front Final Gear Case Oil Level Ball Bearing Oil Seal Inspection 11 34 Inspection 11 11 Propeller Shafts KAF400 A C 11 35 Front Final Gear Case Oil Front Propeller Shaft Removal 11 35 Change secedere 11 11 Front Propeller Shaft Installation 11 35 Front Final Gear Case Removal 11 11 Rear Propeller Shaft Removal 11 37 Front Final Gear Case Installation 11 12 Rear Propeller Shaft Installation 11 38 Front Final Gear Case Propeller Shaft Inspection 11 39 Disassembly 11 12 PMCS Mm 11 40 Front Final Gear Case Assembly 11 13 Front Axle Removal Differential Unit Disassembly 11 15 400 11 40 Differential Unit Assembly 11 17 Front Axle Installation LSD Clutch Torque Inspection 11 18 400 11 40 LSD Clutch Plate Inspection 11 18 Front Axle Removal KAF400 B 11 40 Pinion Gear Unit Disassembly 11 19 Front Axle Installation Pinion Gear Unit Assembly 11 19 400
238. r Filter Housing Bolts 14 Engine Lubrication System Oil Line Plugs 34 in Ib Oil Filter 87 in lb Oil Filter Joint 5 61 in lb Joint KAF400 A C 65 in lb Oil Temperature Sensor KAF400 A C 48 in Ib Engine Oil Drain Plug 14 Engine Oil Drain Plugs Nylon 61 in lb Oil Plug 61 in lb Engine Removal Installation Engine Mounting Bolts and Nuts i 30 Connecting Plate Bolts M8 21 Connecting Plate Bolts M10 41 Rear Axle Brake Bolts 25 Engine Bottom End Connecting Rod Big End Cap Bolts 52 mb Breather Valve Screw 30 in Ib Oil Filter Joint 61 in lb Oil Line Plugs 34 in Ib Crankcase Cover Bolts 16 Engine Oil Drain Plugs 61 in lb Transmission Transmission Cable Holder Bolts 42 4 2 31 Connecting Plate Bolts M8 28 2 9 21 L Connecting Plate Bolts M10 55 5 6 41 L Transmission Case Bolts 8 8 0 90 78 in lb Speed Sensor Cap Bolt 8 8 0 90 78 in Ib Transmission Oil Drain Plug 15 1 5 11 Cover Screws 4 0 0 40 35 in lb Oil Line Plug 9 8 1 0 87 L Shift Shaft Lever Bolt 14 1 4 10 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nm kgf m ftlb Remarks Differential Shift Cable Holder Bolts 8 8 0 90 78 Plug Bolt except Europe Model 15 1 5 11 Shift Shaft Lever Stop Bolt 8 8 0 90 78 in lb Differential Shift Shaft Nut 20 2 0 14 Neutral Switch 15 1 5 11 Reverse Switch Europe Model 15 1 5 11 Positioning Bolt 25 2 5 18 Differential Gea
239. r Housing Bolts 57 5 8 42 L Bearing Holder 137 14 101 L Drive Shaft Nut KAF400B 137 14 101 MO Wheels Tires Wheel Nuts 34 3 5 25 R Final Drive Rear Axle Bracket Bolts 40 4 1 30 Rear Axle Bracket Flange Bolts 49 5 0 36 Front Final Gear Case KAF400 A C Oil Filler Cap 29 3 0 22 Front Final Gear Case Oil Drain Plug 20 2 0 14 Pinion Gear Nut 156 16 115 L Pinion Gear Bearing Holder 98 10 72 Differential Gear Hosing Bolts 49 5 0 36 L Ring Gear Cover Bolts M8 25 2 5 18 Ring Gear Cover Bolts M10 47 4 8 35 E Bevel Gear Case 400 Bevel Gear Case Bolts 20 2 0 14 Yoke Stop Bolt 8 8 0 90 78 in Ib Driven Bevel Gear Slotted Nut 118 12 87 MO Bearing Holder 137 14 101 L Drive Bevel Gear Nut 137 14 101 R MO 2WD 4WD Shift Shaft Nut 20 2 0 14 2WD 4WD Shift Cable Holder Bolts 8 8 0 90 78 in lb L Bearing Housing Bolts 42 4 2 31 KAF400 B Bearing Holder 137 14 101 L Drive Shaft Nut 137 14 101 MO Brakes Push Rod Locknut 18 1 8 13 Master Cylinder Reservoir Cap 3 4 0 35 30 in lb Reservoir Clamp Bolt 6 2 0 63 55 Master Cylinder Mounting Bolts 25 2 5 18 Piston Stop Bolt 8 8 0 90 78 in Ib Brake Pipe Nipples 18 1 8 13 Brake Hose Banjo Bolts 25 2 5 18 Torque and Locking Agent PERIODIC MAINTENANCE 2 7 Steering Steering Wheel Mounting Nut Main Shaft Mounting Bolts Intermediate Shaft Clamp Bolts Steering Gear Assembly Bracket Bolts Rack Guide Spring Cap Locknut Tie rod Locknuts Strut
240. rated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection NOTE Olf the vehicle has just been used wait several minutes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches every part can cause engine seizure e Park the vehicle on level ground and tilt up the seat e Remove Cap Pull out the oil level gauge A and wipe it dry e Apply engine oil to the rubber seal lip A on the dipstick 1004006851 C ENGINE LUBRICATION SYSTEM 6 7 Engine Oil and Oil Filter e Insert the oil level gauge into the oil filler hole securely Always insert the oil level gauge into the oil filler hole so that the taper part A of the cap is facing rearwards Pull out the oil level gauge and check the oil level The oil level should be between the H High and L Low lines A on the dipstick xIf the oil level is too high remove the excess oil using a syringe or some other suitable device or removing the engine oil drain plug drain the excess oil the oil level is too low add the correct amount of oil through the o
241. re e Using the hand tester measure the internal resistance of the sensor across the terminals at the temperatures shown in the table x If the hand tester does not show the specified values re place the sensor Oil Temperature Sensor Resistance Oil Temperature Warning Indicator Control Unit Inspection KAF400 A C e Remove Left Side Cover see Frame chapter Oil Temperature Warning Indicator Control Unit A e Set the hand tester to x1 kO range and make sure the measurements shown in the table Special Tool Hand Tester 57001 1394 xIf the tester readings are not as specified replace the control unit NOTICE Use only Tester 57001 1394 with new battery at room temperature for this test A tester other than the Kawasaki Hand Tester may show different read ings If a meter with a large capacity battery is used the control unit will be damaged 1915003852 C 1915004851 C 16 50 ELECTRICAL SYSTEM Switches Internal Resistance Terminal 32 5 97 5 Tester Lead Connection 32 5 97 5 it KQ eo 25 0 75 0 oo 17 0 51 0 oo 27 5 82 5 27 5 82 5 oo oo 32 5 97 5 28 0 84 0 32 5 97 5 17 0 51 0 25 0 75 0 oo oo oo Tester Lead Connection Oil Temperature Warning Control System C
242. reading the battery will probably not accept a charge It is generally best to replace a battery in this condition x lf the specific gravity of all the cells is 1 270 or more the battery is fully charged Brake Light Switch Inspection e Check the operation of the brake light switch by depress ing the brake pedal The brake light should go on after 10 mm 0 4 in of pedal travel A x If it does not adjust the brake light switch A up or down To change the switch position turn the adjusting nut B Brake Light Switch Timing Standard ON after 10 mm 0 39 in of pedal travel To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment 1818001BS1 C PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures General Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation Pivots and Points Lubricate with Grease Seat Brackets Cargo Bed Mounting Pins Throttle Pedal Pivot Brake Pedal Pivot Transmission Shift Control Lever Pivot Differential Shift Cable Upper End 2WD AWD Shift Lever Pivot KAF400 A C Cables Lubricate w
243. rease to the alternator side journal e Apply engine oil to the crank pin and bearing e Insert the crankshaft into the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high flash point washing and dry them with com pressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact Replace the gear if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches evidence of im proper contact or other damages Replace them if necessary 8 18 ENGINE BOTTOM END Crankshaft and Connecting Rods Connecting Rod Bend Twist e Measure connecting rod bend OSelect an arbor of the same diameter as the connecting rod big end and insert the arbor through the connecting rod big end OSelect an arbor of the same diameter as the piston pin and at least 100 mm 3 937 in long and insert the arbor through the connecting rod small end a surface plate set the big end arbor on V blocks A OWith the connecting rod held vertically use a height gauge B to measure the difference in the height of the small end arbor above the surface plate over a 100 mm 3 937 in length to determine the amount of connecting rod bend connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit 0 2 100 mm 0 0
244. replace it 1K05000BS1 x If the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing sur faces with fine emery cloth if necessary IK05001BS1 10 8 WHEELS TIRES Wheels Rims Wheel Rim Replacement e Remove the wheel see Wheel Removal e Remove the tire from the rim e Remove the air valve and discard it NOTICE Replace the air valve whenever the tire is replaced Do not reuse the air valve Plastic Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F e Install a new air valve in the new rim ORemove the valve cap lubricate the stem with a soap and water solution and pull the stem A through the rim from the inside out until it snaps into place NOTICE Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber e Mount the tire on the new rim e Install the wheel see Wheel Installation 6J05010881 1 05002 5 Tires WHEELS TIRES 10 9 Tire Removal e Remove Wheel see Wheel Removal Valve Core let out the air e Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriora
245. rive Pulley Assembly e Replace the weight pin nuts with new ones e Install the ramp weights A as shown e Tighten Torque Weight Pin Nuts B 7 0 0 70 kgf m 61 in Ib e Check that the ramp weights swing smoothly e Hold the fixed sheave A with the drive pulley holder B in a vise Special Tool Drive Pulley Holder 57001 1628 CONVERTER SYSTEM 5 23 Drive Pulley e Clean the threads of the fixed sheave and spider Install Movable Sheave Spider A and Wear Shoes B OAlign the arrow C on the spider with the arrow D on the movable sheave Olnsert the shoes so that the rubber side faces inward e Put the drive pulley wrench A on the spider B Special Tool Drive Pulley Wrench 57001 1627 e Turn the wrench for tightening Torque Spider 275 N m 28 kgf m 203 ft Ib e Put the spring A in the groove of the spider e Align the arrows B on the drive pulley cover and spider e Install Drive Pulley Cover C e Tighten Torque Drive Pulley Cover Bolts 23 N m 2 3 kgf m 17 ft Ib e Clean the surface of the sheaves with an oil less cleaning fluid Drive Pulley Installation e Refer to the Torque Converter Installation 5 24 CONVERTER SYSTEM Driven Pulley Driven Pulley Removal e Refer to the Torque Converter Removal Driven Pulley Disassembly e Hold the driven pulley holder A with a suitable C clamps B as shown Special Tool Driven Pulley Holder 57001 1630 e Put the dri
246. rom the yoke and remove the insulator B e Using a needle nose pliers remove the brush springs from the brush holder B e Separate the brushes C from the holder and remove the holder from the yoke D Electric Starter System ELECTRICAL SYSTEM 16 37 Starter Motor Assembly e Apply a small amount of grease to the armature shaft A as shown e Do not reuse the snap ring B Replace it with a new one e Inspect the rubber insert A and or boot B for visible damage x If they are damaged replace them e Fitthe notch A in the lead grommet onto the projection B on the end cover C e Grease the pinion gear fork fingers e Set the pinion gear fork so that the fingers fit into the groove in the gear e Fit the notch A in the yoke onto the projection B on the pinion gear fork 16 38 ELECTRICAL SYSTEM Electric Starter System e Engage the hook on the starter solenoid with the hook A on the pinion gear fork B 208048 P Starter Motor Brush Inspection e Measure the overall length of each brush A x If the brushes are shorter than the service limit replace them Carbon Brush Length Standard 10 mm 0 394 in Service Limit 6 mm 0 236 in Brush Spring Inspection e Inspection the brush springs for pitting cracks rusting and burrs Replace the spring if necessary e Inspect the springs for weakened conditions and distor tion Replace the springs if ne
247. rter Circuit Relay Brake Brake Light Switch Battery 30 A Fuse P Gabi ELECTRICAL SYSTEM 16 43 Lighting System Headlight Beam Adjustment e Turn the adjusting screw A on each headlight rim in or out to adjust the headlight vertically Headlight Bulb Replacement e Remove Screws A Collar B Headlight Assembly C e Remove Adjusting Screw A Bolts B and Washers Headlight Cover C e Disconnect Connectors A e Remove Dust Cover A e Push and turn the bulb holder B counterclockwise and remove it 16 44 ELECTRICAL SYSTEM Lighting System e Remove Headlight Bulb A e Insert the new bulb A by aligning the tang B with the notch C in the head light unit e Insert the bulb holder A by aligning the tangs B with the notches C in the head light unit e Push and turn the bulb holder counterclockwise and re move it e Fit the dust cover A with the TOP mark B upward to position light firmly e Push and turn the bulb socket A counterclockwise and remove it 19138012 P ELECTRICAL SYSTEM 16 45 Lighting System e Remove the wedge base type bulb A pull the bulb straight out of the socket B Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Insert the bulb socket A by aligning the longer projec tions B with the longer rec
248. s as a set if either gear is dam aged Ball Bearing Oil Seal Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has rough spots replace it e Inspect the oil seals Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged 6114010151 FINAL DRIVE 11 35 Propeller Shafts KAF400 A C Front Propeller Shaft Removal e Remove Front Final Gear Case Guard see Frame chapter Bottom Guard see Frame chapter e Slide the rubber boot A forward e Push the universal joint B forward C and remove the rear end from the bearing housing Push the rear universal joint A forward fully and remove the front propeller shaft B from the front universal joint Front Propeller Shaft Installation e When installing the cover A press the cover so that the cover surface is flush with the end of the yoke end ODoes not scratch the contact surface B of the oil seal 11060018581 C 11 36 FINAL DRIVE Propeller Shafts KAF400 A C e Insert the propeller shaft A through the hole of the frame
249. switch body and turn the socket clockwise Indicator Light Bulb Replacement e Remove Light Assembly A Lens B e Roll the rubber A up and pull the bulb B out of the socket Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Install Bulb Lens A Light Assembly B 16 48 ELECTRICAL SYSTEM Lighting System Lighting System Circuit Om P Light Switch lgnition Switch Headlights Position Lights Brake Tail Lights Brake Switch 30 A Fuse Battery Parking Brake Light Switch Parking Brake Light 19013002884 C Switches ELECTRICAL SYSTEM 16 49 Brake Light Switch Inspection e Refer to Brake Light Switch Inspection in the Periodic Maintenance chapter Oil Temperature Sensor Inspection KAF400 A C e Remove Oil Temperature Sensor A see Engine Lubrication Sys tem chapter e Suspend the sensor in a container of engine oil so that the heat sensitive portion and threaded portion are sub merged e Suspend an accurate thermometer B with heat sensitive portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperatu
250. t Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level to high Black smoke Air cleaner clogged Main jet too large or fallen off Choke valve stuck closed Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Steering wheel hard to turn Steering shaft bearing damaged Steering shaft lubrication inadequate Steering shaft bent Steering gear assembly damaged Tire air pressure too low LSD clutch maladjusted KAF400 A C Noise when turning KAF400 A C Damaged side gear or pinion front final gear case Worn clutch friction plates Front final gear case Worn clutch spring Front final gear case Steering wheel shakes or excessively vibrates Tire s worn Suspension arm bushing worn Tie rod joint worn Wheel rim warped Axle shaft bearing worn Steering wheel mount loose Steering bolt or nut loose not properly Troubleshooting Guide Steering wheel pulls to one side Frame bent Wheel misalignment Suspension arm bent or twisted Steering shaft bent Steering gear assembly damaged Front or rear tire air pressure unbalanced Shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber damaged Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Br
251. tally turning over Disconnect the ground cable E ud e first and then the positive When completed with the 620 7 e service first connect the positive cable to the positive J m terminal of the battery then the negative cable to the negative terminal DISASSEMBL Y ASSEMBLY 68020248 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts GB02004B Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Qus V F NE A 1907 68020058 5 Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle 8020018 GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 680
252. te the gear case breather hose correctly according to the Appendix chapter e Adjust the front final gear case oil see Front Final Gear Case Oil Change the Periodic Maintenance chapter Front Final Gear Case Disassembly e Remove Front Final Gear Case see Front Final Gear Case Re moval Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove Cil Seal C Pry open the staking A of the pinion gear bearing holder B with a small chisel Unscrew the pinion gear bearing holder using the socket wrench A Special Tool Socket Wrench Hex 48 57001 1401 Front Final Gear Case KAF400 A C FINAL DRIVE 11 13 e Remove Ring Gear Cover Bolts 8 A first Ring Gear Cover Bolts M10 B Ring Gear Cover C OUsing the ply points D split the front final gear case x If the case seems too difficult to break free install suitable M8 bolts as shown And then drive the bolt end using a copper mallet to remove the cover e Remove Ring Gear Assembly A Shim B both sides e To remove the pinion gear unit A tap the case B with a plastic or rubber mallet x If the pinion gear seems too difficult to remove free apply heat with a drier to expand the case NOTICE Do not heat the case with a torch This will warp the case Front Final Gear Case Assembly e Visually check the pinion gear and ring gear for scoring chipping or other damage Replace the bevel gears
253. te the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims tightly Tire Installation e Inspect the rim e Check the tire for wear and damage e Replace the air valve with a new one NOTICE Replace the air valve whenever the tire is replaced Do not reuse the air valve e Lubricate the tire beads and rim flanges with a soap and water solution or water WARNING Do not use any lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation and a hazardous condition may result e Install the tire on the rim using a suitable commercially available tire changer e Lubricate the tire beads again and center the tire on the rim e Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 kgf cm 36 psi WARNING Overinflating a tire can cause it to explode causing serious injury or death Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than maximum pressure 060008 5 IK06001B 5 10 10 WHEELS TIRES Tires e Check to see that the bead lines A on both s
254. ter the battery is fully charged the trouble may be that there is not enough acid in that one cell In this case only sulfuric acid solution may be added to correct the specific gravity x If a fully charged battery not in loses its charge after 2 to 7 days or if the specific gravity drops markedly the battery is defective The self discharge rate of a good battery is only about 196 per day Sulfation here A Sediment here B 1008003BS1 16 22 ELECTRICAL SYSTEM Charging System Alternator Rotor and Stator Removal e Tilt up the cargo bed e Remove Left Rear Wheel see Wheels Tires chapter Carburetor see Fuel System chapter 2WD AWD Shift Cable Holder KAF400 A C Models Starter Motor for Stator Coil Removal e Remove Fan Housing Bolts A e Remove the stoppers A of the fan housing e Remove the fan housing A as shown ELECTRICAL SYSTEM 16 23 Charging System e Remove Ignition Coil Lead Connector A disconnect Ignition Coil Bolts B Ignition Coil C e Hold the alternator rotor with a suitable holder A e Remove Alternator Rotor Bolt B Washer C and Plate D Cooling Fan E e Screw the alternator rotor bolt A e Tap the bolt end sharply and squarely to break the rotor loose and remove the alternator rotor B Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism e Disconnect Alternator
255. termine the cause and then replace it with a new fuse of proper amperage 10 A Fuse Case A Brown Lead B 30 A Fuse Case C White Lead D Fuse Inspection e Remove the fuse e Inspect the fuse element A x If it is blown out replace the fuse Before replacing a blown fuse B always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components HP15000BS1 C APPENDIX 17 1 Appendix Table of Contents Troubleshooting E 17 2 Cable Wire Hose Routing diee etre mte o ber uu 17 6 17 2 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Wiring open or shorted Ignition switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor trouble Pinion or ring gear worn Engine won t turn over Valve seizure Rocker arm seizur
256. tet tese Oil iPump e et eet er d rege eeu Oil Pump Installation enne nennen nnne BUR Gillen DEE Relief Valve 6 9 Relief Valve Installation 6 10 Relief Valve Inspection 6 10 CTee 6 11 Oil Sereen Removal xc RE cae cO ER ERR 6 11 Oil Screen Installation 6 11 Oil Screen Cleaning lnspection tdeo Cer bed edenda 6 11 Oil Temperature Sensor KAF AOO AC 6 12 Oil Temperature Sensor Removal pp 6 12 Oil Temperature Sensor Installation pp 6 12 6 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 6 3 Exploded View Torque No F R k astener Nm ftlb emarks 1 Oil Line Plugs 3 9 0 40 34 in Ib L 2 Oil Filter 9 8 1 0 87 3 Oil Filter Joint 6 9 0 70 61 in Ib 4 Joint KAF400 A C 7 4 0 75 65 in Ib 5 Temperature Sensor KAF400 A C 5 4 0 55 48 in Ib 6 Oil Plug 6 9 0 70 61 in Ib 7 Oil Drain Plugs 20 2 0 14 8 Engine Oil Drain Plug Nylon 6 9 0 70 61 in Ib EO Apply engine oil G Apply grease L Apply a non permanent locking agent to the threads R Replacement Parts A KAF400A C Model B KAF400B Model 6 4 ENGINE LUBRICATION SYSTEM Spec
257. the axle x If they are badly worn or chipped replace the axle with new one e Apply molybdenum disulfide grease to the axle splines and oil seal e Insert the axle and tap the end of the axle lightly and install the axle NOTE OThe axle shaft must not come off easily Front Axle Removal KAF400 B e Remove Front Wheel see Wheels Tires chapter Cotter Pin A e Remove Axle Nut A Washer B Front Axle C Front Axle Installation KAF400 B e Tighten Torque Front Axle Nuts 147 N m 15 kgf m 108 ft Ib Axles FINAL DRIVE 11 41 Rear Axle Removal e Refer to Transmission Case Removal in the Transmission chapter for rear axle removal A Rear Right Axle B Rear Left Axle Rear Axle Installation e Refer to Transmission Case Installation in the Transmis sion chapter for rear axle installation e Adjust Transmission Oil see Transmission Oil Change in the Periodic Maintenance chapter Axle Inspection e Visually inspect the splines of the axle xIf they are twisted badly worn or chipped replace the axle with a new one e Check that the ball joint works smoothly without rattling or sticking x If it does not the bearings of the joint are damaged Re place the front axle with a new one Dust Boot Inspection KAF400 A C e Visually inspect the boots A if the front axles are noisy during operation x If the dust boot is torn worn or deteriorated replace it 1L07003B
258. the direction the belt s printed information A such as numbers manu facture s name or arrow marks is facing so that it may be reinstalled on the pulleys to rotate in the same direc tion as originally installed e Remove Drive Pulley and Drive Belt e Using the flywheel amp pulley holder A and attachments B remove the driven pulley bolt C and washers Special Tools Flywheel amp Pulley Holder 57001 1605 or 57001 1343 Pulley Holder Attachment 57001 1472 e Remove the driven pulley A from the transmission shaft by screwing the drive pulley puller bolt B clockwise while holding the driven pulley with the flywheel amp pulley holder C as shown Special Tool Drive Pulley Puller Bolt 57001 1429 Torque Converter Installation e Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone and blow off it by compressed air WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Driven Pulley Transmission Shaft Tapered Portion A Transmission Shaft Threads Portion B Movable Sheave Tapered Portion C Driven Pulley Bolt Threads Portion D Two Washers IF04006BS1 C 5 12 CONVERTER SYSTEM Torque Converter Drive Pulley Crankshaft Tapered Portion A Crankshaft Threads Portion B Fixed Sheave Tapered Portion C Drive Pulley Bolt Thr
259. the distance A Rear is greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slipping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are built in and require no adjustment A Rear B Front Amount of Toe in Distance A and B are measured at hub height Toe in Adjustment e Lift the front wheels off the ground e Apply a heavy coat of chalk near the center of the front tires e Using a needle nose scriber make a thin mark near the center of the chalk coating while turning the wheel e Set the wheels so that the marks on the tires are at the front side and at the level of the axle height e Ground the front wheels e Set the steering wheel straight ahead e At the level of the axle height measure the distance be tween the scribed lines with a measure e Move the vehicle rearward until the marks on the front tires are at the rear side and at the same level as the axle e Measure the distance A between the scribed lines e Subtract the measurement of the front from the measure ment of the rear to get the toe in Toe in of Front Wheels Standard 0 20 mm 0 0 79 in at 1G x If the toe in is not the specified value perform the follow ing procedure e Check the length A of the tie r
260. the push rods and mark them so they can be installed in their original positions during assembly e Pull the camshaft A out of the crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the following Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Install the tappets in their original positions e Align the punch marks A on the crankshaft gear and on the camshaft gear Camshaft and Tappets ENGINE BOTTOM END 8 9 e Install the crankcase cover see Crankcase Cover Instal lation e Install the push rods see Push Rod Installation in the Engine Top End chapter e Mount the rocker arms on the push rods and install the valve clearance adjusting nuts and the lock screws Torque Valve Adjusting Nut Lock Screws 6 9 N m 0 70 kgf m 61 in Ib e Adjust the valve clearance see Valve Clearance Adjust ment in the Periodic Maintenance chapter e Install the cylinder head cover Camshaft Disassembly e Remove Spring A e Do not remove the ACR Automatic Compression Re lease weight B Camshaft Assembly e After assembling the camshaft check the following item OWhile shaking the camshaft ACR weight A swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact Replace the
261. the shock absorber damper unit x If oil leakage is noted the shock absorber should be re placed to renew the oil seal e Visually inspect the rubber bushings A in the upper and or lower mountings of the rear shock absorber x If they are worn cracked hardened or otherwise dam aged replace them with new ones INO4000BS1 C SUSPENSION 13 9 Front Suspension Arms Front Suspension Arm Removal e Remove Front Cargo Compartment see Frame chapter Front Wheel see Wheels Tires chapter Brake Panel Assembly see Brakes chapter Tie rod End A see Knuckle Removal in the Steering chapter e Remove Cotter Pin A Strut Clamp Bolt and Nut B e Remove Suspension Arm Bolts A Front Suspension Arm Joint Nut B Suspension Arm with Steering Knuckle C e Install a suitable nut A on the stud of the joint end and tap the nut to free the joint from the suspension arm B 13 10 SUSPENSION Front Suspension Arms Front Suspension Arm Installation e Replace the front suspension arm pivot nuts with new ones e Clean the sealing surface and the tapered portion of the steering knuckle joint and the tapered hole of the front suspension arm or the tapers will not fit snugly e Install Front Suspension Arm Joint Boot Sealing Surface A Good B Bad C e When the front suspension arm pivot bolts are tightened install the arm joint in the steering knuckle to position the
262. the special grease tube nozzle in the bore of the housing and squeeze the tube A until the grease comes out from the joint bearing e Tap the shaft end A straight with a plastic hammer until it is locked by the circlip e Squeeze all of the special grease A into the new boot B and slide the boot onto the outboard joint C 11 44 FINAL DRIVE Axles Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot e Hold the axle at this setting Standard Length of Assembling Outboard 273 7 mm 10 78 in A Open the edge of the boot in order to equalize the air pressures e Tighten the large band A and bend the tangs securely to hold down the end of the band Maximum Outside Diameter of Band 80 2 mm 3 16 in After tightening the outside diameter e While the band is held at the diameter above tap down the tangs A of the band Inboard Joint Boot Removal e Remove Front Axle see Front Axle Removal Boot Bands A e Scrap the removed boot bands e Slide the joint boot B toward the outboard joint e Remove the retaining ring A e Separate to the axle shaft ANNER HL MN HK13003BS1 C 11078014 Axles FINAL DRIVE 11 45 e Remove the steel balls A e Slide the cage B toward the outboard joint e Remove Circlip A Special Tool O
263. tiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use one of these for check ing the bevel gears e Assemble the front final gear case see Front Final Gear Case Assembly Do not apply liquid gasket during ad justment e Turn the pinion gear shaft for one revolution in the drive and reverse coast direction while creating a drag on the ring gear e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth OThe tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE Olf the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern FINAL D
264. tion and measure the resistance between the negative brushes and starter motor yoke x If the meter dose not read close to 0 the yoke assembly is faulty Replace it Negative Brush to Ground Resistance Close to 00 Pinion Clutch Inspection e Remove the pinion clutch e Turn the pinion gear by hand The pinion gear should turn counterclockwise freely but should not turn counterclock wise x If the pinion clutch dose not operate as it should or if it makes noise replace the pinion clutch Starter Circuit Relay Inspection e Remove Starter Circuit Relay Neutral A Starter Circuit Relay Brake B 1011002BS1 C ELECTRICAL SYSTEM 16 41 Electric Starter System e Connect the hand tester A and 12 V battery B to the starter circuit relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected gt 00 When battery is disconnected Q Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 1911001852 C 16 42 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit BR BR VETTE BK W BK W 2 _ BK R N BK R BK W BK Y BL BK Y O SCECPRE ff 1 11003BW3 C Ignition Switch Starter Motor with Relay Starter Circuit Relay Neutral Neutral Switch Sta
265. tor body when holding it in a vise e Install 10118010 P Starter Motor Lead A Nut B Electric Starter System ELECTRICAL SYSTEM 16 35 e Connect a 12 V battery to the starter solenoid A as shown OConnect the battery negative cable B to the starter motor body OConnect the battery positive cable C to the stud ter minal D e Connect the switching lead E to the battery positive terminal Testing Starter Motor Criteria When switching lead is connected Pinion gear must move outward When switching lead is disconnected Pinion gear must return quickly x If the starter motor does not work as specified the starter motor is defective Replace the starter motor Starter Motor Disassembly e Remove Starter Motor see Starter Motor Removal Starter Motor Lead Nut A Starter Motor Lead B e Remove Nuts A Starter Solenoid B e Remove Starter Motor Through Bolts A Pinion Gear Cover B e Slip the actuating arm C from the pinion gear 16 36 ELECTRICAL SYSTEM Electric Starter System e Pull the armature A from the yoke B e Separate the front stopper A and rear stopper B each other and remove the front stopper to left side C as shown the figure e Push the rear stopper to right side D and remove the snap ring E as shown the figure e Pull the rear stopper and pinion gear F from the armature shaft e Gently pull the end cover A f
266. ts and Nuts A e Remove Muffler Mounting Bolts A Muffler B ENGINE TOP END 4 19 Exhaust Pipe and Muffler Exhaust Pipe and Muffler Installation e Replace the exhaust pipe gaskets with new ones as fol lows KAF400A C A C Front amp Rear Gasket P No 11061 0132 D B D 50 mm 1 97 in KAF400B ef e Front Gasket P No 11061 0133 B 48 mm 1 89 in C Rear Gasket P No 11061 0132 EE S D 50 mm 1 97 in e Tighten the bolts and nuts following the tightening se quence 1 2 3 or 2 1 3 Torque Exhaust Pipe Clamp Nuts 1 20 N m 2 0 kgf m 14 ft lb Muffler Clamp Nuts 2 31 N m 3 2 kgf m 23 ft lb Muffler Mounting Bolts 3 31 N m 3 2 23 ft lb lt e After installation thoroughly warm up the engine wait un 9 til the engine cools down and then retighten the clamp nuts and muffler mounting bolts 1E06003BS1 C Exhaust Pipe and Muffler Inspection e Before removing check for signs of leakage at the ex haust pipe gasket in the cylinder head and at the muffler clamp x If there are signs of leakage around the exhaust pipe gas ket it should be replaced If the muffler to exhaust pipe joint leaks tighten the clamp e Check the exhaust pipe and muffler for dents cracks rust and holes xIf the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise Spark Arrester Clea
267. tward OTighten Torque Bearing Holder 137 N m 14 kgf m 101 ft Ib Special Tool Socket Wrench Hex 41 57001 1402 e Install the oil seals to the left transmission case as shown Left Transmission Case A Oil Seal B 0 5 mm 0 02 in C Bushing D Flush E Oil Seal F Flush Oil Seal H Flush I Oil Line Plug J e Apply a non permanent locking agent to the plug and tighten it Torque Oil Line Plug 9 8 N m 1 0 kgf m 87 in Ib Detail Z 1405001BN3 C TRANSMISSION 9 23 Transmission Case e Replace all circlips that were removed with new ones NOTE OTo install a circlip without damage first fit the circlip onto the shaft and then expand it just enough to install Hence use a suitable gear to push the circlip into place e Apply transmission oil Ball and Needle Bearings Bearing of Shaft Slide of Shaft Slide of Governor Gear Slide and Tooth of Gears Shifters Spacers e Apply grease Lip of Oil Seals O rings e Check that each gear sprocket and shifter spins or slides freely on its shaft without binding after assembly e Install Governor Assembly see Fuel System chapter Governor Shaft Shift Shaft 9 24 TRANSMISSION Transmission Case e Install KAF400 A C Transmission Shaft A Circlip B Collar C Reverse Driven Sprocket D Spacer E Shifter F Circlip G Washer H Spacer I High Gear J Needle Bearing K Low Gear L Drive Gear M S
268. ual apply the specific oil or grease as specified A X 68020218 Direction of Engine Rotation When rotating the crankshaft by hand the free play 3 amount of rotating direction will affect the adjustment Ss tate the crankshaft to positive direction counterclockwise viewed from output side 8020028 Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R leads must be connected to those of the same color 68020238 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification KAF400 A1 Left Side View 18038002 P KAF400 A1 Right Side View The KAF400 C1 is identical to the KAF400 A1 in every aspect controls features and specifications except the camouflage surface treatment and weight 1 8 GENERAL INFORMATION Model Identification KAF400 B1 Left Side View KAF400 B1 Right Side View 18038006 18038007 P General Specifications GENERAL INFORMATION 1 9 Items KAF400 A1 A6F A9F C1 C6F C9F KAF400 B1 B6F B9F Dimensions Overall Length Overall Width Overall Height Wheelbase Tread Front Rear Gr
269. ump the brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir This bleeds the air from the master cylinder end of the line Brake Fluid BRAKES 12 9 e Remove the wheel for extra clearance see Wheels Tires chapter e Connect a clear plastic hose A to the bleed valve at the wheel cylinder running the other end of the hose into a container B Brake Panel NOTE OStart with the rear left or right wheel and finish with the front left or right wheel e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake pedal until it becomes hard and apply the brake pedal and hold it 2 Quickly open and close the bleed valve while holding the brake pedal applied 3 Release the brake pedal e Tighten Torque Bleed Valves 7 8 N m 0 80 kgf m 69 e Repeat the previous step for each wheel e When air bleeding is finished add fluid up to the upper level in the reservoir e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings e Install the removed parts Torque Master Cylinder Reservoir Cap 3 4 0 35 kgf m 30 in Ib 12 10 BRAKES Brake Pedal and Master Cylinder Brake Pedal Play Inspection e Refer to the Brakes in the Periodic Maintenance chapter Master Cylinder Re
270. und 0 Gap Snap Pin Washer Pin 8 14 mm 0 32 0 55 in 1 2 3 4 5 6 7 8 17 8 APPENDIX Cable Wire and Hose Routing 1808045884 C 1 Headlight Lead 2 Quick Rivet 3 Clamp 4 Harness 5 Red Tape Right Side 6 Headlight Lead 7 Clamp 8 Main Harness 9 Differential Lock Shift Cable 10 Choke Cable 11 Transmission Shift Cable 12 2WD AWD Shift Cable KAF400 A C 13 Throttle Cable 14 Brake Pipe APPENDIX 17 9 Cable Wire and Hose Routing Qoo AIO Ord po c 12 13 14 1808046884 C Horn Europe Model Washer Collar Screw Horn Lead Europe Model Screw Steering Gear Assembly Main Harness Differential Lock Shift Cable Choke Cable Transmission Shift Cable 2WD AWD Shift Cable KAF400 A C Throttle Cable Brake Pipe 17 10 APPENDIX Cable Wire and Hose Routing R DN 2 S gt Th d ii 5 xx ES E Section DA Ce CH S ue s lt 22 lt 1808260884 C 1 Main Harness 2 Differential Lock Shift Cable 3 Choke Cable 4 Transmission Shift Cable 5 2WD AWD Shift Cable KAF400 A C 6 Throttle Cable 7 Brake Pipe 8 14 mm 0 55 in 9 20 mm 0 79 in 10 Rear Left Brake Cable 11 Rear Right Brake Cable 12 Bands 13 45 APPENDIX 17 11 Cable Wire and Hose Routing
271. utside Circlip Pliers B 57001 144 e Remove Inner Race A Cage B Inboard Joint Boot C Boot Band D Inboard Joint Boot Installation e Install New Small Band A New Inboard Joint Boot B Cage C e Install the inner race A so that the flat side B faces outboard joint m 11 46 FINAL DRIVE Axles e Install Circlip A Special Tool Outside Circlip Pliers 57001 144 e Slide the cage B on the inner race and install the steel balls C e Apply the special grease A to the steel balls and cage e Squeeze about half a tube 30 grams of the special grease A into the bearing cup B e Insert the balls and cage assembly in the bearing cup strongly e Install the new retaining ring A so that the opening B is aligned with one of the projections C HK10004BS1 C Axles FINAL DRIVE 11 47 e Tighten the small band e Squeeze the remaining special grease A into the inboard joint boot B e Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot e Hold the axle at this setting Standard Length of Assembling Inboard 173 5 mm 6 83 in A e Open the edge of the boot in order to eqalize the air pres sures e Tighten the large band A OAssemble it the same as the outboard joint boot noting this setting Maximum Outside Diameter of Band 75 7 mm 2 98 in After tightening t
272. ve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Miscellaneous Throttle valve won t fully open Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Front final gear case oil viscosity too high KAF400 A C Drive train trouble Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Fuel air mixture incorrect Main jet clogged or wrong size Fuel level too low Air cleaner clogged poorly sealed or miss ing Compression high Carbon built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Converter and or belt excessive heating Belt dirty or worn Drive or driven pulley sheave dirty or worn Driven pulley spring broken or weak Drive pulley spring broken or weak Idle speed too high Converter fan damaged Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Front final gear case overheating KAF400 A C Insufficient oil Bevel gears maladjusted LSD clutch maladjusted Cooling system component incorrect Fan blade damaged Screen air passages clogged Converter Operation Faulty Belt slipping Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low Drive pull
273. ven pulley A and spring holder B on the holder e Tighten the nut C and compress the spring with the spring holder e Remove the circlip A with circlip pliers B Special Tool Outside Circlip Pliers 57001 144 e Remove Nut A Spring Holder B Circlip C CONVERTER SYSTEM 5 25 Driven Pulley e Remove Ramp A Spring B Movable Sheave C Spacer D Fixed Sheave E IF07015BS2 C xIf the ramp A does not come off easily face the ramp downward and tap it lightly e Remove Screws A Wear Shoes B Bolts C Shims D IF07016BS2 C 5 26 CONVERTER SYSTEM Driven Pulley Driven Pulley Inspection x If the sheave surfaces A appear damaged replace the sheaves e Replace any sheave which has uneven wear on the belt contacting surface Straight Edge B the guide bushings A are damaged or worn replace the movable sheave Sheave Bushing Inside Diameter Standard 38 016 38 100 mm 1 497 1 500 in Service Limit 38 3 mm 1 51 in x If the splines A of the fixed sheave B and ramp C are damaged or worn replace them x If the spring is damaged or worn replace the spring Spring Free Length A Standard 105 mm 4 13 in Converter Driven Pulley Shoe Inspection e Refer to the Converter System in the Periodic Mainte nance Chapter 17207000851 Driven Pulley CONVERTER SYSTEM 5 27 Bushing Installation e Press th
274. ver the filter bottom with a clean cloth so as not to spill the engine oil out of the filter Any spilled oil should be wiped up completely e Replace the filter with a new one e When installing the oil filter be careful of the following OApply oil to the gasket A before installation OTighten the filter with the filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 9 8 N m 1 0 kgf m 87 OPour in the specified type and amount of oil e Thoroughly warm up the engine and check for oil leakage and the oil level see Oil Level Inspection in the Engine Lubrication System chapter Transmission Transmission Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Place an oil pan beneath the transmission case e Remove the transmission oil drain plug A and let the oil drain completely e Replace the gasket with a new one e After the oil has completely drained out install the drain plug with the gasket Torque Transmission Oil Drain Plug 15 N m 1 5 kgf m 11 ft Ib e Fill the transmission case with a good quality oil as spec ified in the table Transmission Oil Type API GL 5 Hypoid gear oil Viscosity SAE90 above 5 C 41 F or SAE80 below 5 C 41 F Capacity KAF400A C 2 4 L 2 5 US qt KAF400B 2 2 L 2 3 US qt Oil Level Between H and L lines on dipstick e Check the oil level se
275. with a known good unit 1909002851 1909003851 Ns 1009004BS1 16 28 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection KAF400A9F B9F C9F e Remove Regulator Rectifier see Regulator Rectifier Removal e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier x If the tester readings are not as specified replace the regulator rectifier Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit Terminal B D A B D Tester Lead Connection 1909016851 C ELECTRICAL SYSTEM 16 29 Charging System Charging System Circuit G W G W 1 Ignition Switch 2 Alternator 3 Regulator Rectifier KAF400 A1 B1 C1 A6F A8F B6F B8F C6F C8F Models 4 Regulator Rectifier KAFA00A9F ACF B9F BCF C9F CAF Models 5 Battery 6 30 A Fuse 7 Load G W G W 1009015BW3 C 16 30 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spar
276. x If free play is not correct adjust it e Remove the front cargo compartment see Frame chap ter e Loosen the locknut A and turn the push rod B to obtain the correct amount of free play e Tighten Torque Push Rod Locknut 18 N m 1 8 kgf m 13 ft Ib e Check the brake for good braking power and no brake drag A WARNING Insufficient free play can cause brake heating and drag resulting in skidding and loss of control which could cause an accident resulting in serious injury or death Be sure the brake free play is adjusted to the specification PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Brake Master Cylinder Cup and Dust Cover Replacement e Remove the master cylinder see Master Cylinder Re moval in the Brakes chapter e Remove the piston stop bolt A and washer B e Remove the dust cover C and then the retainer D with the circlip pliers Special Tool Inside Circlip Pliers 57001 143 ORemove the piston assembly two pistons by lightly tap the master cylinder on a wooden block Pistons E Springs F Secondary Cup G Primary Cup H Master Cylinder I OBe careful of the secondary cup A direction B 1514800465 P e Assemble the master cylinder OClean all the parts including the master cylinder with brake fluid or alcohol and apply brake fluid to the removed parts and the inner wall of the cylinder NOTICE Use only brake fluid isopropy
277. y oil that may spill with a high flash point solvent 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures e After the oil has completely drained out install the drain plug with a new aluminum gasket and tighten it Torque Front Final Gear Case Oil Drain Plug 20 N m 2 0 kgf m 14 ft Ib e Fill the gear case up to the bottom A of filler opening B with the oil specified below Front Final Gear Case Oil Type API GL 5 or GL 6 hypoid gear oil for LSD Limited Slip Differential gears Viscosity SAE90 GL 6 or SAE140 GL 5 Capacity 0 35 L 0 37 US qt Oil Level Filler opening level NOTE O GL 5 or GL 6 indicate a quality and additive rating e Be sure the O ring C is in place and tighten the filler cap Torque Front Final Gear Case Oil Filler Cap 29 N m 3 0 kgf m 22 ft Ib Brakes Brake Fluid Level Inspection With the vehicle on level ground check that the fluid level in the reservoir is between the upper MAX and lower MIN level lines OLook the fluid level through the hole A in the control panel x If the fluid level is lower than the lower level line check for fluid leaks in the brake lines and fill the reservoir to the upper level line A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line co

When inserting the cotter pin, if the slots in the nut do

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