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KAWASAKI MULE 4×4 SERVICE MANUAL Pdf Download | ManualsLib.Kawasaki MULE 610 4×4 Service Manual
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KAWASAKI MULE TRANS 4X4 OWNER'S MANUAL Pdf Download | ManualsLib.Kawasaki Mule 4010 Trans 4x4 Owner's Manual
Hole 5. Turn the pivot arm. Turn the governor arm. Carburetor Throttle Full Open 8. Throttle Full Open 9. Governor Arm Clamp Nut Standard: If the clearance is not within the specified range, adjust the clearance by adding or removing the shims.
Pull the choke knob until the starter lever [B] on the carburetor begins to turn; If the cable does not move freely after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable.
If the idle speed is out of the specified range, adjust it. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents to clean the carburetor. If the gasket is not in good condition, replace it. If there are any cracks, replace the float.
If the element is very dirty or damaged, replace the ele- ment. Turn the main switch OFF. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Flow Chart Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Water Pump Page Specifications — — — 18 psi Thermostat Air Bleeder Bolt Intake Manifold 2.
Air Bleeder Bolt Water Pipe 3. Thermostat 4. Radiator Cap 5. Reservoir Tank Filter 2. Thermo Valve 3. White Mark 4. Coolant Inlet 5. Coolant Outlet 6. Level the tube to the inlet pipe. Do not bulge the tube as a dotted line. Face the projection on the valve body to the carburetor.
If the cap is removed, the coolant will flow out from the reservoir tank. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passages. Re- place the mechanical seal [A] or O-ring [B]. The radiator fan may start even if the ignition switch is off. If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully straighten them. The cap at the radiator has no valve. If the measurement is out of the specified range, replace the thermostat. Thermostat Valve Opening Temperature Avoid sharp bending, kinking, flattening, or twisting. Cylinder Head Cylinder Compression Measurement Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp M: Apply molybdenum disulfide grease.
Grind the seating surface only until it is smooth. If the free length is less than the service limit, replace the valve spring with a new one. Valve Spring Free Length Standard: Service Limit: If the valve guide has worn past the service limit, replace the cylinder head.
Valve Guide Inside Diameter 6. Standard: Service Limit: 6. If the bearing has worn past the service limit, replace the rocker arm with a new one. Rocker Arm Inside Diameter Standard: Service Limit: Rocker Arm Push Rod Inspection If there are signs of leakage around the exhaust pipe gas- ket, it should be replaced.
Air Cleaner Air Cleaner Housing Removal Air Cleaner Element Removal Torque Converter Torque Converter Removal Torque Converter Installation Torque Converter Case Removal Drive Belt Fit the joint location of the seal with the top of the case. Fit the seal into groove of the case. Do not twist the seal. T8: 1. Belt Deflection — — — Belt Width Spider Wear Guide Clearance — If any measurements exceed the service limit, replace the belt. Belt Width Standard: Cover Bushing Inside Diameter [A] Sheave Bushing Inside Diameter [B] Spring Free Length [A] Standard: If the ramps [A] or the wear shoes [B] are damaged or worn, replace the ramp or the shoes.
If the wear shoe contact area width [A] is greater than the service limit, replace the shoe [B]. Engine Oil Flow Chart Engine Oil and Oil Filter Oil Level Inspection Oil Filter Removal Oil Filter Installation Oil Pump and Relief Valve Oil Pump and Relief Valve Removal L mark 2. R mark T1: 4. Page Specifications Outer Rotor Housing Inside Diameter Rotor Housing Depth If any rough spots are found during the 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.
Service Limit Engine Removal Engine Installation Crankcase Cover Crankcase Cover Removal Crankcase Cover Installation Camshaft and Tappets Camshaft Removal Camshaft Installation Camshaft Inspection Cam Wear Cylinders and Pistons O: Apply engine oil.
Crankshaft Runout Less than 0. TIR 0. TIR If any journal has worn past the service limit, replace the camshaft with a new one. Camshaft Journal Diameter The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. Oversize Piston and Rings 0. Standard: Service Limit: 0. If the journal has worn past the service limit, replace the crankshaft with a new one.
Crankshaft Main Journal Diameter Page Specifications Shifter Groove Width 9. Page Transmission Case Splitting If any one of them has been removed, re- place it with a new one.
At this time, increase the engine speed slightly. If the cable movement is not free, if the cable is frayed, or if the housing is kinked, replace the cable. Shift Arm Pin Diameter [A] 7. If any one of them has been removed, replace it with a new one. Do not forget to tighten the adjuster nuts [B]. Torque - Shift Shaft Stop Bolt: 7.
When there is toe-in, 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.
This helps the tire beads slip off the rim flanges. Then stop the vehicle. If any plates show signs of damage, or if the friction plates have worn past the service limit, replace the friction plates and steel plates as a set. To decrease preload, increase the size of the shim s or collar. Replace the bevel gears as a set if either gear is dam- aged. If they are twisted, badly worn, or chipped, replace the shafts. If it does not, the bearings of the joint are damaged.
If the dust boot is torn, worn, deteriorated, or leaks grease, replace it. If any joint does not work smoothly without rattling or stick- ing, the joint bearing is damaged. Replace the axle. If they are badly worn or chipped, replace the axle. Replace if the lips are misshapen, discolored indicating that the rubber has deteriorated , hardened, or been oth- erwise damage.
Do not use fluid from a container that has been left unsealed or that has been open for a long time. Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 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 Standard: If free play is not correct, adjust it.
If the cylinder or piston shows any damage, replace them. Bend and twist the rubber hose while examining Replace it if any cracks or bulges are noticed. Use the brake drum remover, stud nuts, and rotor puller special tools to remove the drums. If the springs are damaged in any way, replace them. Count the number of notches clicks during lever travel.
If lever travel is not correct, adjust it. If the cable does not move freely after lubricating, or if the cable is frayed, or if the cable housing is kinked, replace the cable. Strut Spring Replacement In addition to the standard springs, hard springs are avail- able. The hard springs stiffen the strut action and accelerate the rebound damping.
If the front suspension arm is damaged in any way, re- place it. If the leaf spring is damaged in any way, replace it. Replace any bushings or damper that are worn, cracked, hardened, or otherwise damaged. This distance should be the specified value for both the left and right tie-rods. Tie- rod Length distance between groove and locknut Standard: G: Apply grease.
This hole should not be pluged both side. Fix the bolt to inside from outside. Large corner side. Liners and fitting parts. L: Apply a non-permanent locking agent. After tightening the nuts, the seat must be moved up and down smoothly. Front [G] Lock Lever [H] 5 mm 0. If the lever angles rest within the specified range, latch the cargo bed with the hooks. SS: Apply silicone sealant. Reverse Light Switch 2. Reverse Light Learn and ob- serve all the rules below.
No shipping fee, No waiting nervously for the postal delivery, you can start doing your repairs right away! Broken down on the trail or site and have a smart phone? What a easy way to find your problem and repair it on the spot, no down time on the job site, With our Downloadable Repair Manual PDFs you instantly have access to the material needed to get you running again. Kind of tough to do that with a paper manual. Skip to content. This manual service is packed with all the information you need and also is very simple to use.
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