Kawasaki Mule 1000
KAWASAKI MULE 1000 - SERVICE MANUAL
KAWASAKI MULE 1000 - SERVICE MANUAL - English Workshop Manual to UTV Kawasaki Mule 1000. INDEX: 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 Idle Speed Valve Clearance (when cold) Belt Width Belt Deflection shims Wear Shoe Width 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 Spark Plug Gap Specific Gravity Brake Light Switch Timing Idle Speed Choke Knob Free Play Cylinder Compression Rocker Arm Push Rod Runout Cylinder Head Warp Valve Seating Surface Outside Diameter Valve Seating Surface Width Standard Valve Spring Free Length Valve Head Thickness Valve Stem Bend Valve Stem Diameter Valve Guide Inside Diameter Valve/Guide Clearance (Wobble Method) Driven Pulley Drive Pulley Cover Bushing Inside Diameter [A] Sheave Bushing Inside Diameter [A] Spring Free Length [A] Shoe Side Clearance Sheave Bushing Inside Diameter Spring Free Length [A] Inner and 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 Cam Lobe Height Crankcase Side Camshaft Journal Diameter Crankcase Cover Side Camshaft Journal Diameter Camshaft Bearing Inside Diameter (Crankcase) Camshaft Bearing Inside Diameter (Crankcase Cover) Piston Ring/Groove Clearance Piston Ring Thickness Piston Ring End Gap Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Piston Diameter Cylinder Inside Diameter Cylinder Bore Out-Round Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankcase Side Crankshaft Main Journal Diameter Crankshaft Main Bearing Inside Diameter (Crankcase Side) Balancer Shaft Journal Diameter Balancer Shaft Bearing Inside Diameter (Crankcase) Balancer Shaft Bearing Inside Diameter (Crankcase cover) Shift Fork Ear Thickness Shifter Groove Width [A] Reverse Chain 20-Link Length [B] Shifter Block Outside Diameter Shifter Groove Width Shift Shaft Pin Diameter [A] Shifter Groove Width [B] Toe-in of Front Wheels Tie-rod Length (distance between flange end and locknut) Maximum Tire Air Pressure (to seat beads when cold) Tire Air Pressure (when cold) LSD Clutch Torque Outside Friction Plate Thickness [A] Inside Friction Plate Thickness [B] Bevel Gear Backlash Bevel Gear Backlash Drive Gear Shims [4] Standard Length of Assembling: Standard Length of Assembling: Recommended Brake Fluid Spring Action Battery Troubleshooting Guide Regulator/Rectifier Output Voltage Stator Coil Resistance Ignition Coil Air Gap Ignition Coil Winding Resistance Testing Solenoid Testing Starter Motor Carbon Brush Length Commutator Groove Depth Commutator Outside Diameter Commutator Runout Armature Winding Resistance Commutator to Shaft Resistance Positive Brush to Ground Resistance Negative Brush to Ground Resistance Testing Relay Oil Temperature Sensor Resistance Internal Resistance Unit: kO TOC Read OWNER'S MANUAL before operating. EMISSION CONTROL INFORMATION . PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (UNITED STATES MO 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 KAF400-A1 Left Side View KAF400-A1 Right Side View KAF400-B1 Left Side View KAF400-B1 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 Idle Speed Inspection Idle Speed Adjustment Air Cleaner Element Cleaning Fuel Hoses And Connections Inspection Fuel Hoses Replacement Fuel Filter Replacement Fuel System Cleanliness Inspection Engine Top End Valve Clearance Inspection Valve Clearance Adjustment Torque - Spark Arrester Cleaning Converter System Drive Belt Inspection Drive Belt Deflection Inspection Drive Belt Deflection Adjustment Torque - Converter Driven Pulley Shoe Inspection Converter Air Cleaner Element Cleaning/Inspection Converter Dust or Water Drain Engine Lubrication System Engine Oil Change Torque - Oil Filter Replacement Special Tool - Special Tool - Torque - Transmission Transmission Oil Change Torque - Wheels/Tires Wheels Nuts Tightness Inspection Torque - Tire Wear Inspection Final Drive (KAF400-A/C models) Front Final Gear Case Oil Change Torque - Torque - Brakes Brake Fluid Level Inspection Brake Fluid Change Torque - Torque - Brake Pedal Play Inspection Torque - Brake Master Cylinder Cup and Dust Seal Replacement Special Tool - Torque - Brake Hose and Pipe Inspection Brake Hose and Pipe Replacement Torque - Torque - Brake Wear Inspection Brake Wheel Cylinder Assembly Replacement Sealant - Torque - Parking Brake Lever Inspection Steering Steering Inspection Steering Joint Dust Boot Inspection Frame Seat Belt Inspection Torque - Electrical System Spark Plug Cleaning/Inspection Spark Plug Gap Inspection Electrolyte Level Inspection Electrolyte Specific Gravity Inspection Brake Light Switch 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 Torque - Governor Assembly Removal Governor Assembly Installation Governor Assembly Inspection Choke Knob Free Play Inspection Choke Knob 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 - Carburetor Disassembly Carburetor Assembly Torque - Carburetor Cleaning Carburetor Inspection Pilot Screw Setting Air Cleaner Element Removal Air Cleaner Element Installation Air Cleaner Housing Removal Air Cleaner Housing Installation Torque - Air Cleaner Housing Dust and/or Water Installation Fuel Pump Removal Fuel Pump Installation Torque - Fuel Pump Inspection Fuel Filter Removal Fuel Filter Installation Fuel Filter Inspection Fuel Tank Removal Fuel Tank Installation Fuel Tank Cleaning/Inspection ENGINE TOP END Compression Gauge, 20 kgf/cm : Cylinder Compression Measurement Special Tools - Cylinder Head Removal Cylinder Head Installation Torque - Torque - Push Rod Inspection Valve Mechanism Removal/Installation Rocker Arm Inspection Cylinder Head Warp Valve Clearance Inspection Valve Clearance Adjustment Valve Seat Inspection Valve Seat Repair 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) Exhaust Pipe Removal Muffler Removal Exhaust Pipe and Muffler Installation Torque - Exhaust Pipe and Muffler Inspection Spark Arrester Cleaning CONVERTER SYSTEM Outside Circlip Pliers: Air Cleaner Element Removal Air Cleaner Element Cleaning/Inspection Air Cleaner Housing Removal Torque Converter Removal Special Tool - Torque - Special Tool - Special Tools - Special Tool - Torque Converter Installation Special Tools - Torque - Special Tool - Torque - Torque - Torque Converter Case Removal Torque Converter Case Installation Torque - Drive Belt Removal Drive Belt Installation Drive Belt Inspection Drive Belt Deflection Inspection Drive Belt Deflection Adjustment Drive Pulley Removal Drive Pulley Disassembly Special Tool - Special Tool - Drive Pulley Inspection Spider Shoe Side Clearance Adjustment Special Tool - Bushing Installation Special Tool - Special Tool - Drive Pulley Assembly Torque - Special Tool - Special Tool - Torque - Torque - Drive Pulley Installation Driven Pulley Removal Driven Pulley Disassembly Special Tool - Special Tool - Driven Pulley Inspection Converter Driven Pulley Shoe Inspection Bushing Installation Special Tool - Driven Pulley Assembly Torque - Special Tool - Special Tool - Special Tool - Driven Pulley Installation ENGINE LUBRICATION SYSTEM WARNING Oil Level Inspection Engine Oil Change Oil Filter Replacement Oil Pump Removal Oil Pump Installation Oil Pump Inspection Relief Valve Removal Relief Valve Installation Relief Valve Inspection Oil Screen Removal Oil Screen Installation Oil Screen Cleaning/Inspection Oil Temperature Sensor Removal Oil Temperature Sensor Installation Torque - ENGINE REMOVAL/INSTALLATION Alignment Jig: Engine Removal Engine Installation Special Tool - Torque - ENGINE BOTTOM END Piston Ring Compressor Grip: Crankcase Cover Removal Crankcase Cover Assembly Special Tool - Crankcase Cover Installation Torque - Camshaft, Tappet Removal Camshaft, Tappet Installation Torque - Camshaft Disassembly Camshaft Assembly Camshaft Inspection Camshaft Bearing/Journal Wear Piston Removal Piston Installation Special Tools - Torque - Piston Cleaning Piston Ring and Ring Groove Wear Piston Ring End Gap Piston Pin, Piston Pin Hole, and Connecting Rod Wear Piston Diameter Cylinder Inside Diameter Connecting Rod Removal Connecting Rod Installation Crankshaft Removal Crankshaft Installation Cleaning/Inspection Connecting Rod Bend/Twist Connecting Rod Big End/Crankpin Width Wear Connecting Rod Big End Bearing/Crankpin Wear Crankshaft Runout Crankshaft Main Bearing/Journal Wear Balancer Shaft Removal Balancer Shaft Installation Balancer Shaft Bearing/Journal Wear The function of the breather is to create a negative pressure in Breather Valve Removal Breather Valve Installation Torque - Breather Valve Inspection TRANSMISSION Outside Circlip Pliers: CAUTION Transmission Oil Level Inspection Transmission Oil Change Transmission Case Removal Transmission Case Installation Special Tool - Torque - Torque - Transmission Case Disassembly Special Tool - Special Tool - Special Tool - Transmission Case Assembly Torque - Torque - Special Tool - Torque - Special Tool - Sealant - Torque - Transmission Cable Installation Torque - Transmission Shift Cable Inspection Shift Rod Bending Shift Fork Ear and Shifter Groove Wear Transmission and Shift Mechanism Inspection 2WD/4WD Shift Cable Adjustment 2WD/4WD Shift Cable Lubrication 2WD/4WD Shift Cable Inspection 2WD/4WD Shift Mechanism Removal 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 - Torque - Differential Shift Mechanism Inspection Differential Gear Removal Differential Gear Installation Torque - Differential Gear Inspection Bearing Replacement Special Tools - Special Tool - Ball Bearing Inspection Needle Bearing Inspection Oil Seal Inspection WHEELS/TIRES Jack: Toe-in is the amount that the front wheels are closer together i Toe-in Adjustment Torque - Wheel Removal Special Tool - Wheel Installation Torque - Wheel (Rim) Inspection Wheel (Rim) Replacement Tire Removal Tire Installation Tire Wear 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 Front Final Gear Case Disassembly Special Tool - Special Tool - Front Final Gear Case Assembly Torque - Torque - Special Tool - Sealant - Torque - Special Tool - Differential Unit Disassembly Differential Unit Assembly Torque - LSD Clutch Torque Inspection LSD Clutch Plate Inspection Pinion Gear Unit Disassembly Special Tool - Special Tool - Pinion Gear Unit Assembly Torque - Front Final Bevel Gear Adjustment Torque - Special Tool - Special Tool - Front Final Gear Case (Backlash-Related Parts) Correct Tooth Contact Pattern: No adjustment is required. Incorrect Tooth Contact Patterns (Example 1) Incorrect Tooth Contact Patterns (Example 2) Bevel Gear Inspection Differential Gear Inspection Ball Bearing Inspection Oil Seal Inspection Driven Bevel Gear Removal Driven Bevel Gear Installation Torque - Driven Bevel Gear Disassembly Special Tools - Driven Bevel Gear Assembly Special Tools - Torque - Special Tool - Special Tool - Drive Bevel Gear Removal Special Tool - Drive Bevel Gear Installation Special Tool - Torque - Bevel Gear Adjustment Special Tool - Special Tool - Torque - Bevel Gear Case (Backlash-Related Parts) Bevel Gear Inspection Ball Bearing/Oil Seal Inspection Front Propeller Shaft Removal Front Propeller Shaft Installation Rear Propeller Shaft Removal Rear Propeller Shaft Installation Torque - Propeller Shaft Inspection Front Axle Removal (KAF400-A/C) Front Axle Installation (KAF400-A/C) Front Axle Removal (KAF400-B) Front Axle Installation (KAF400-B) Torque - Rear Axle Removal Rear Axle Installation Axle Inspection Dust Boot Inspection (KAF400-A/C) Front Axle Joint Boot Replacement (KAF400-A/C) Special Tool - Special Tool - Ball Bearing Inspection Grease Seal Inspection BRAKES Front Brake Rear Brake Clutch Spring Compressor: Brake Fluid Recommendation Brake Fluid Level Inspection Brake Fluid Change Brake Line Air Bleeding Torque - Torque - Brake Pedal Play Inspection Master Cylinder Removal Master Cylinder Installation Torque - Master Cylinder Disassembly/Assembly Master Cylinder Inspection Brake Hose and Pipe Inspection Brake Hose and Pipe Replacement Brake Drum Removal Special Tool - Special Tools - Brake Drum Installation Special Tool - Special Tool - Torque - Torque - Brake Drum Wear Brake Panel Assy Removal Brake Panel Assy Installation Sealant - Sealant - Bond - Torque - Brake Panel Disassembly Brake Panel Assembly Torque - Wheel Cylinder Removal/Installation Wheel Cylinder Assembly Wheel Cylinder Inspection Brake Shoe Lining Wear Brake Shoe Spring Inspection Grease Seal Replacement Special Tool - Special Tool - Special Tool - Torque - Parking Brake Lever Travel Adjustment Parking Brake Cable Lubrication/Inspection SUSPENSION Outside Circlip Pliers: Strut (Front Shock Absorber) Removal Strut (Front Shock Absorber) Installation Torque - Rear Shock Absorber Preload Adjustment Special Tool - Rear Shock Absorber Removal Rear Shock Absorber Installation Torque - Rear Shock Absorber Inspection Front Suspension Arm Removal Front Suspension Arm Installation Torque - Front Suspension Arm Inspection Swingarm Removal Swingarm Installation Torque - Swingarm Inspection Swingarm Joint Replacement Special Tool - Special Tool - STEERING Inside Circlip Pliers: Steering Wheel Free Play Inspection Steering Wheel Centering Torque - Steering Wheel and Steering Shaft Removal Steering Wheel and Steering Shaft Installation Torque - Steering Gear Assembly Removal Steering Gear Assembly Installation Torque - Steering Gear Preload Adjustment Torque - Tie-rod Length Adjustment Dust Boot Inspection Steering Knuckle Removal Steering Knuckle Installation Torque - Knuckle Bearing Removal Special Tool - Special Tool - Knuckle Bearing Installation Special Tool - Special Tool - Knuckle Joint Removal Special Tool - Special Tool - Knuckle Joint Installation Special Tool - Special Tool - FRAME Seat Removal Seat Installation Seat Belt Removal Seat Belt Installation Torque - Control Panel Removal Glove Compartment Removal Front Cargo Hood Removal Front Cargo Compartment Removal Front Cargo Compartment Installation Cargo Bed Removal Cargo Bed Assembly Cargo Bed Installation Cargo Bed Latch Position Inspection Cargo Bed Latch Position Adjustment Front Bar Removal Front Bar Installation Torque - Rear Bar Removal Rear Bar Installation Torque - Front Fender Installation Front Guard Removal Front Guard Installation Floor Center Panel Removal Floor Center Panel Installation Front Final Gear Case Guard Removal Front Final Gear Case Guard Installation Bottom Guard Removal Bottom Guard Installation Transmission Case Guard Removal Transmission Case Guard Installation Center Cover Removal Center Cover Installation Side Covers Removal Side Covers Installation Guard Plate Removal Guard Plate Installation ELECTRICAL SYSTEM Spark Plug Wrench, Hex 21: Oil Temperature Warning Indicator Light [A] There are a number of important precautions that are musts when Wiring Inspection Battery Removal Battery Installation Electrolyte Level Inspection Electrolyte Specific Gravity Inspection Charging Condition Inspection Initial Charging Ordinary Charging Battery Charging Rate/Time Table Battery Test Charging Special Tool - Alternator Rotor and Stator Removal Alternator Rotor and Stator Installation Torque - Torque - Torque - Charging System Operational Inspection Stator Coil Resistance Regulator/Rectifier Inspection Charging System Circuit WARNING Spark Plug Removal Special Tool - Spark Plug Installation Torque - Spark Plug Cleaning/Inspection Spark Plug Gap Inspection Ignition Coil Removal Ignition Coil Installation Torque - Ignition Coil inspection Special Tool - Ignition System Circuit Starter Motor Removal Starter Motor Installation Torque - Starter Solenoid Inspection Starter Motor Inspection Starter Motor Disassembly Starter Motor Assembly Starter Motor Brush Inspection Brush Spring Inspection Armature Inspection Yoke Assembly Inspection Pinion Clutch Inspection Starter Circuit Relay Inspection Electric Starter Circuit Headlight Beam Adjustment Headlight Bulb Replacement Tail/Brake Light Replacement Light Switch Bulb Replacement Indicator Light Bulb Replacement Lighting System Circuit Brake Light Switch Inspection Oil Temperature Sensor Inspection (KAF400-A/C) Oil Temperature Warning Indicator Control Unit Inspection (KAF40 Special Tool - Oil Temperature Warning Control System Circuit Switch Inspection Neutral Switch Connections Reverse Light Switch Connections (Europe Model) Horn Switch Connections (Europe Model) Fuse Removal Fuse Installation Fuse 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 (KAF400-A/C): Cooling system component incorrect: 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 (KAF400-A/C): 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 1000 - Workshop Manual / Repair Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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