kawasaki mule 3010 trans 4x4
SERVICE MANUAL
KAWASAKI MULE 3010 TRANS 4X4 - SERVICE MANUAL - English Service Manual to UTV Kawasaki Mule 3010 Trans 4x4. CONTENTS: TABLES LIST OF ABBREVIATIONS Units of Mass: Units of Volume: Units of Force: Units of Length: Units of Torque: Units of Pressure: Units of Speed: Units of Power: Basic Torque for General Fasteners of Engine Parts Basic Torque for General Fasteners of Frame Parts Throttle Pedal Free Play Idle Speed Water and Coolant Mixture Ratio (Recommended) Belt Width Wear Shoe Width Valve Clearance (when cold) Engine Oil Transmission Oil Tire Tread Depth Standard Tire Front Final Gear Case Oil Brake Pedal Free Play Brake Drum Inside Diameter Brake Shoe Lining Thickness Parking Brake Lever Travel Steering Wheel Free Play Brake Light Switch Timing Spark Plug Gap Throttle Link Lever Bolt/Shim Clearance Shims Choke Cable Free Play Valve Closing Temperature (for reference) Water Pump Shaft Diameter Water Pump Shaft Bearing Inside Diameter Radiator Cap Relief Pressure Thermostat Valve Opening Temperature Cylinder Compression Cylinder Head Warp Valve Seating Surface Outside Diameter Valve Seating Surface Width Valve Spring Free Length Valve Head Thickness Valve Stem Bend Valve Stem Diameter Valve Guide Inside Diameter Valve/Guide Clearance (Wobble Method) Rocker Shaft Diameter Rocker Arm Inside Diameter Rocker Arm Push Rod Runout Belt Deflection Spacers Spider Wear Guide Clearance Cover Bushing Inside Diameter [A] Sheave Bushing Inside Diameter [B] Spider Wear Guide Thickness [B] Spring Free Length [A] Sheave Bushing Inside Diameter Spring Free Length [A] Inner Rotor/Outer Rotor Clearance Inner Rotor Shaft Diameter [A] Outer Rotor Diameter [B] Outer Rotor Width [C] Inner Rotor Shaft Bearing Inside Diameter [A] Outer Rotor Housing Inside Diameter [B] Rotor Housing Depth [C] Cam Height (Inlet) Cam Height (Exhaust) Camshaft Journal Diameter Camshaft Bearing Inside Diameter Piston Ring/Groove Clearance (Top, Second) Piston Ring End Gap (Top, Second) Cylinder Inside Diameter Piston Diameter Oversize Piston and Rings Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing/Crankpin Clearance Crankpin Diameter Connecting Rod Big End Inside Diameter Crankshaft Runout Crankshaft Main Journal Diameter Crankshaft Main Bearing Inside Diameter Shift Arm Pin Diameter [A] Shifter Block Inside Diameter [B] Shifter Block Outside Diameter [C] Shifter Groove Width [D] Drive Chain 20-Link Length [B] Shifter Block Outside Diameter [A] Shifter Groove Width [B] Shifter Block Outside Diameter Shifter Groove Width Shift Arm Pin Diameter [A] Shifter Groove Width [B] Toe-in of Front Wheels Maximum Tire Air Pressure (to seat beads when cold) Tire Air Pressure (when cold) LSD Clutch Torque Outside Friction Plate Thickness Inside Friction Plate Thickness Using Spring Scale Using Torque Wrench Bevel Gear Backlash Bevel Gear Backlash Recommended Brake Fluid Drum Press-fitting Force (Torque) Spring Action Tie- rod Length (distance between boot end and locknut) Kawasaki-recommended chargers Battery Terminal Voltage Terminal Voltage: 11.5 ~ less than 12.5 V Terminal Voltage: less than 11.5 V Regulator/Rectifier Output Voltage Stator Coil Resistance Ignition Coil Winding Resistance Ignition Coil Primary Peak Voltage Pickup Coil Resistance Connections Pickup Coil Peak Voltage Carbon Brush Length Commutator Diameter Testing Switch Testing Relay Fuel Pump Leads Fuel Pump Relay Internal Resistance (Tester Range: × 1 kO) Radiator Fan Motor Leads Radiator Fan Switch Resistance Coolant Temperature Warning Light Switch Resistance TOC Read OWNER'S MANUAL before operating. EMISSION CONTROL INFORMATION PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL ONLY) FOREWORD GENERAL INFORMATION Before starting to perform an inspection service or carry out a Battery Ground Edges of Parts Solvent Cleaning vehicle before disassembly Arrangement and Cleaning of Removed Parts Storage of Removed Parts Inspection Replacement Parts Assembly Order Tightening Sequence Tightening Torque Force Gasket, O-ring Liquid Gasket, Locking Agent Press Ball Bearing and Needle Bearing Oil Seal, Grease Seal Circlips, Cotter Pins Lubrication Direction of Engine Rotation Electrical Wires KAF620-J1 Left Side View KAF620-J1 Right Side View Prefixes for Units: Units of Temperature: PERIODIC MAINTENANCE The scheduled maintenance must be done in accordance with this c The following tables list the tightening torque for the major fa Inside Circlip Pliers: Fuel System Throttle Pedal Free Play Inspection Throttle Pedal Free Play Adjustment Full Throttle Pedal Position Adjustment Idle Speed Inspection Idle Speed Adjustment Fuel System Cleanliness Inspection Fuel Filter Inspection Intake Chamber Water Draining External Carburetor Mechanism Cleaning Fuel Hoses And Connections Inspection Fuel Hoses Replacement Air Cleaner Element Cleaning Air Cleaner Housing Dust and/or Water Inspection Cooling System Radiator Cleaning Radiator Hose and Connection Inspection Coolant Draining Coolant Filling Torque - Coolant Filter Inspection Converter System Drive Belt Inspection Converter Driven Pulley Shoe Inspection Air Cleaner Element Cleaning/Inspection Converter Dust or Water Draining Engine Top End Valve Clearance Inspection Valve Clearance Adjustment Special Tool - Torque - Spark Arrester Cleaning Engine Lubrication Oil and/or Filter Change Torque - Oil Filter Removal Special Tool - Oil Filter Installation Transmission Transmission Oil Change Torque - Wheels/Tires Wheels Nuts Tightness Inspection Torque - Tire Inspection Final Drive Front Final Gear Case Oil Change Torque - Torque - Brakes Brake Fluid Level Inspection Brake Fluid Changing Torque - Brake Pedal Free Play Adjustment Torque - Brake Master Cylinder Cup and Dust Seal Replacement Special Tool - Torque - Brake Hose and Pipe Inspection Brake Hose and Pipe Replacement Torque - Brake Wear Inspection Brake Wheel Cylinder Assembly Replacement Torque - Parking Brake Lever Travel Adjustment Steering Steering Wheel Free Play Inspection Steering Joint Dust Boot Inspection Frame Seat Belt Inspection Electrical System Brake Light Switch Adjustment Spark Plug Cleaning/Inspection Spark Plug Gap Inspection General Lubrication Pivots and Points: Lubricate with Grease. Cables: Lubricate with Rust Inhibitor. Cables: Lubricate with Motor Oil. Bolts, Nuts, and Fasteners Tightness Inspection Nut, Bolt, and Fasteners to be checked FUEL SYSTEM Throttle Pedal Free Play Inspection Throttle Pedal Free Play Adjustment Full Throttle Pedal Position Adjustment Throttle Cable Installation Throttle Cable Lubrication Throttle Cable Inspection Control Panel Assembly Removal Control Panel Assembly Installation Governor Arm and Throttle Link Removal Governor Arm Installation Torque - Governor Assembly Removal Governor Assembly Installation Governor Assembly Inspection Throttle Link Lever Installation Torque - Maximum Engine Speed Inspection Choke Cable Free Play Inspection Choke Cable Free Play Adjustment Choke Cable Installation Choke Cable Lubrication Choke Cable Inspection Idle Speed Inspection Idle Speed Adjustment Fuel System Cleanliness Inspection Carburetor Removal Carburetor Installation Torque - Torque - Sealant - Torque - Carburetor Disassembly Carburetor Assembly Torque - Carburetor Cleaning Carburetor Inspection Coolant Filter Cleaning Coolant Valve Inspection Air Cleaner Element Cleaning Air Cleaner Housing Removal Air Cleaner Housing Installation Torque - Sealant - Torque - Air Cleaner Housing Dust and/or Water Inspection Fuel Pump and Fuel Filter Removal Fuel Pump Installation Fuel Filter Installation Fuel Filter Inspection Fuel Tank Removal Fuel Tank Installation Fuel Tank Cleaning/Inspection COOLING SYSTEM Kawasaki Bond (Silicone Sealant): Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Water Pump Removal Water Pump Installation Torque - Water Pump Inspection Radiator Removal Radiator Inspection Radiator Cleaning The radiator cap at the reservoir tank has the pressure relief v Radiator Cap Inspection Thermostat Removal Thermostat Installation Thermostat Inspection Hose and Pipe Installation Hose Inspection Radiator Fan Switch, Coolant Temperature Warning Light Switch Re Radiator Fan Switch, Coolant Temperature Warning Light Switch In Sealant - Torque - Radiator Fan Switch, Coolant Temperature Warning Light Switch In ENGINE TOP END Outside Circlip Pliers: Cylinder Compression Measurement Cylinder Head Removal Cylinder Head Installation Torque - Torque - Cylinder Head Disassembly and Assembly (Valve Mechanism Removal Special Tool - Cylinder Head Warp Valve Clearance Inspection Valve Clearance Adjustment Valve Seat Inspection Valve Seat Repair Special Tools - Special Tools - Valve Spring Free Length Valve Head Thickness Valve Stem Bend Valve Stem Diameter Valve Guide Inside Diameter Measuring Valve/Guide Clearance (Wobble Method) Rocker Arm/Shaft Wear Rocker Arm Push Rod Inspection Exhaust Pipe Removal Muffler Removal Exhaust Pipe and Muffler Installation Exhaust Pipe and Muffler Inspection Spark Arrester Cleaning CONVERTER SYSTEM Outside Circlip Pliers: Air Cleaner Housing Removal Air Cleaner Element Removal Air Cleaner Element Cleaning/Inspection Torque Converter Removal Special Tool - Torque Converter Installation Torque - Torque - Torque Converter Case Removal Drive Belt Removal Drive Belt Installation Drive Belt Deflection Inspection Drive Belt Deflection Adjustment Torque - Drive Belt Inspection Drive Pulley Disassembly Special Tool - Special Tool - Drive Pulley Assembly Torque - Special Tool - Torque - Torque - Spider/Wear Guide Clearance Adjustment Drive Pulley Inspection Bushing Installation Driven Pulley Disassembly Special Tools - Special Tool - Driven Pulley Assembly Torque - Special Tools - Special Tool - Driven Pulley Inspection Bushing Installation ENGINE LUBRICATION SYSTEM Oil Filter Wrench: WARNING Oil Level Inspection Oil and/or Filter Change Oil Filter Removal Oil Filter Installation Oil Pump and Relief Valve Removal Oil Pump and Relief Valve Installation Oil Pump and Relief Valve Inspection Oil Screen Removal Oil Screen Installation Oil Screen Cleaning/Inspection Oil Pressure Switch Removal Oil Pressure Switch Installation Sealant - Torque - ENGINE REMOVAL/INSTALLATION Engine Removal Engine Installation Torque - ENGINE BOTTOM END Piston Pin Puller Assembly: Crankcase Cover Removal Crankcase Cover Installation Torque - Camshaft Removal Camshaft Installation Camshaft Inspection Cam Wear Camshaft Bearing/Journal Wear Piston Removal Special Tool - Piston Installation Special Tools - Torque - Piston Ring, Piston Ring Groove Wear Piston Ring End Gap Cylinder Inside Diameter Piston Diameter Boring, Honing Connecting Rod Removal Connecting Rod Installation Crankshaft Removal Crankshaft Installation Crankshaft Cleaning Connecting Rod Bend/Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing/Crankpin Wear Torque - Torque - Crankshaft Runout Crankshaft Main Bearing/Journal Wear Breather Valve Removal Breather Valve Installation Breather Valve Inspection RANSMISSION Outside Circlip Pliers: CAUTION Transmission Oil Level Inspection Transmission Oil Change Transmission Case Removal Transmission Case Installation Torque - Transmission Case Splitting Transmission Case Assembly Sealant - Torque - Transmission and Hi/Low Shift Cables Installation Shift Lever Position Inspection Shift Lever Position Adjustment Transmission Shift Cable Inspection Transmission Removal Special Tool - Special Tool - Transmission Installation Torque - Transmission and Shift Mechanism Inspection Hi/Low Shift Cable Installation Hi/Low Shift Cable Inspection Hi/Low Gear and Shift Mechanism Removal Special Tool - Hi/Low Gear and Shift Mechanism Installation Torque - Hi/Low Gear and Shift Mechanism Inspection 2WD/4WD Shift Cable Adjustment 2WD/4WD Shift Cable Lubrication 2WD/4WD Shift Cable Inspection 2WD/4WD Shift Mechanism Removal Special Tool - 2WD/4WD Shift Mechanism Installation Torque - 2WD/4WD Shift Mechanism Inspection Differential Shift Cable Adjustment Differential Shift Cable Lubrication Differential Shift Cable Inspection Differential Shift Mechanism Removal Differential Shift Mechanism Installation Torque - Differential Shift Mechanism Inspection Differential Gear Removal Differential Gear Installation Torque - Differential Gear Inspection Bearing Replacement Special Tools - Special Tool - Torque - Special Tool - Ball Bearing Inspection Needle Bearing Inspection Oil Seal Inspection WHEELS/TIRES Toe-in is the amount that the front wheels are closer together i Toe-in Adjustment Torque - Wheel Removal Wheel Installation Torque - Wheel (Rim) Inspection Wheel (Rim) Replacement Tire Removal Tire Installation Tire Inspection FINAL DRIVE Bearing Puller: Front Final Gear Case Oil Level Inspection Torque - Front Final Gear Case Oil Change Front Final Gear Case Removal Front Final Gear Case Installation Torque - Front Final Gear Case Disassembly Front Final Gear Case Assembly Torque - Differential Unit and Ring Gear Disassembly Differential Unit and Ring Gear Assembly Torque - LSD Clutch Torque Inspection LSD Clutch Plate Inspection Pinion Gear Unit Disassembly Special Tools - Special Tool - Pinion Gear Unit Assembly Torque - Front Final Bevel Gear Adjustment Special Tool - Special Tool - Special Tool - Special Tool - Bevel Gear Inspection Differential Gear Inspection Tapered Roller Bearing Inspection Ball Bearing Inspection Oil Seal Inspection Bevel Gear Case Removal Bevel Gear Case Installation Torque - Bevel Gear Case Disassembly Special Tools - Special Tools - Special Tool - Special Tool - Special Tools - Bevel Gear Case Assembly Torque - Drive Bevel Gear Removal Special Tool - Drive Bevel Gear Installation Torque - Bevel Gear Adjustment Special Tool - Bevel Gear Inspection Ball Bearing Inspection Oil Seal Inspection Damper Inspection Propeller Shaft Removal Propeller Shaft Installation Propeller Shaft Inspection Front Axle Removal Front Axle Installation Torque - Rear Drive Shaft and Axle Removal Rear Drive Shaft and Axle Installation Drive Shaft and Axle Inspection Dust Boot Inspection Front Axle Joint Boot Replacement Special Tool - Special Tool - Special Tool - Ball Bearing Inspection Grease Seal Inspection BRAKES Inside Circlip Pliers: Brake Fluid Recommendation Brake Fluid Level Inspection Brake Fluid Changing Brake Line Air Bleeding Torque - Brake Pedal Free Play Adjustment Master Cylinder Removal Master Cylinder Installation Torque - Master Cylinder Disassembly Master Cylinder Assembly Master Cylinder Inspection Brake Hose and Pipe Inspection Brake Hose and Pipe Replacement Brake Drum Removal Special Tools - Brake Drum Installation Special Tools - Torque - Brake Drum Wear Brake Panel Removal Brake Panel Installation Torque - Wheel Cylinder Assembly Wheel Cylinder Inspection Brake Shoe Lining Wear Brake Shoe Spring Inspection Parking Brake Lever Travel Adjustment Parking Brake Cable Lubrication Parking Brake Cable Inspection SUSPENSION Steering Stem Nut Wrench: Strut (Front Shock Absorber) Removal Strut (Front Shock Absorber) Installation Torque - Strut Spring Replacement Torque - Rear Shock Absorber Preload Adjustment Special Tool - Rear Shock Absorber Removal Rear Shock Absorber Installation Torque - Shock Absorber Inspection Front Suspension Arm Removal Front Suspension Arm Installation Torque - Front Suspension Arm Inspection Leaf Spring Removal Leaf Spring Installation Torque - Torque - Leaf Spring Inspection STEERING Steering Wheel Position Adjustment Steering Wheel Free Play Inspection Steering Wheel Centering Torque - Steering Wheel and Steering Shaft Removal Steering Wheel and Main Shaft Installation Torque - Steering Gear Assembly Removal Steering Gear Assembly Installation Torque - Steering Gear Preload Adjustment Torque - Tie-rod Length Adjustment Torque - Steering Joint Dust Boot Inspection Steering Knuckle Removal Steering Knuckle Installation Torque - FRAME Front Seat Removal Front Seat Installation Rear Seat Removal Rear Seat Installation Seat Belt Removal Seat Belt Installation Torque - Torque - Control Panel Removal Glove Compartment Removal Front Cargo Hood Removal Front Cargo Compartment Removal Cargo Bed Removal Cargo Bed Installation Front Bar Removal Front Bar Installation Torque - Rear Bar Removal Rear Bar Installation Torque - Center Bar Removal Center Bar Installation Torque - Cargo Bed Latch Position Inspection Cargo Bed Latch Position Adjustment Front Cover Removal Front Fender Removal Radiator Side Cover Removal Radiator Side Cover Installation Radiator Side Cover Flap Removal Floor Center Panel Removal Rear End Sub-frame Removal Rear End Sub-frame Installation Torque - ELECTRICAL SYSTEM Crankcase Splitting Tool Assembly: Horn [A] There are a number of important precautions that are musts when Battery Removal Battery Installation Torque - Battery Activation Precautions Interchange Charging Condition Inspection Refreshing Charge Alternator Rotor and Stator Removal Special Tool - Alternator Rotor and Stator Installation Torque - Charging System Operational Inspection Stator Coil Resistance Regulator/Rectifier Inspection Charging System Circuit WARNING Spark Plug Removal/Installation Torque - Spark Plug Gap Inspection Spark Plug Cleaning/Inspection Ignition Coil Removal Ignition Coil Installation Ignition Coil Inspection Ignition Coil Primary Peak Voltage Inspection Special Tools - Pickup Coil Removal Pickup Coil Inspection Pickup Coil Peak Voltage Inspection Special Tool - Ignition System Inspection Ignition System Circuit Starter Motor Removal Starter Motor Installation Torque - Starter Motor Disassembly Starter Motor Assembly Carbon Brush Inspection Yoke Inspection Brush Plate Inspection Commutator Cleaning/Inspection Armature Inspection Pinion Gear Inspection Starter Switch Inspection Starter Circuit Relay Inspection Electric Starter Circuit The fuel pump does not operate when the ignition switch is turne Fuel Pump Operational Inspection Fuel Pump Relay Internal Resistance Fuel Pump and Relay Circuit Radiator Fan Circuit Inspection Radiator Fan Motor Inspection Radiator Fan Circuit Headlight Beam Adjustment Headlight Bulb Replacement Tail/Brake Light Replacement Lighting System Circuit Brake Light Switch Adjustment Switch Inspection Radiator Fan Switch Inspection Coolant Temperature Warning Light Switch Inspection Fuse Removal Fuse Installation Fuse Inspection Wiring Inspection APPENDIX NOTE Engine Doesn't Start, Starting Difficulty: Starter motor not rotating: Starter motor rotating but engine doesn't turn over: Engine won't turn over: No fuel flow: Engine flooded: No spark; spark weak: Compression Low: Poor Running at Low Speed: Spark weak: Fuel/air mixture incorrect: Compression low: Other: Poor Running or No Power at High Speed: Firing incorrect: Fuel/air mixture incorrect: Compression low: Knocking: Miscellaneous: Overheating: Firing incorrect: Fuel/air mixture incorrect: Compression high: Engine load faulty: Converter and/or belt excessive heating: Lubrication inadequate: Front final gear case overheating: Coolant incorrect: Cooling system component incorrect: Over Cooling Converter Operation Faulty: Belt slipping: Converter engagement speed too low: Converter engagement speed too high: Shifting too quickly: Shifting too slowly: Gear Shifting Faulty: Doesn't go into gear: Jumps out of gear: Overshifts: Abnormal Engine Noise: Knocking: Piston slap: Valve noise: Other noise: Abnormal Drive Train Noise: Converter noise: Transmission noise: Final drive noise: Abnormal Frame Noise: Shock absorber noise: Brake noise: Other noise: Exhaust Smokes Excessively: White smoke: Black smoke: Brown smoke: Handling and/or Stability Unsatisfactory: Steering wheel hard to turn: Noise when turning: Steering wheel shakes or excessively vibrates: Steering wheel pulls to one side: Shock absorption unsatisfactory: Brake Doesn't Hold Battery Discharged: Battery Overcharged:
Kawasaki Mule 3010 Trans 4x4 Service Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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