Kawasaki MULE 3010 TRANS 4 × 4 User manual

Category
Motorcycles
Type
User manual

This manual is also suitable for

MULE 3010 TRANS 4 × 4
Utility Vehicle
Service Manual
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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 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Cooling System 4 j
Engine Top End 5 j
Converter System 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Engine Bottom End 9 j
Transmission 10 j
Wheels/Tires 11 j
Final Drive 12 j
Brakes 13 j
Suspension 14 j
Steering 15 j
Frame 16 j
Electrical System 17 j
Appendix 18 j
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Property of www.SmallEngineDiscount.com - Not for Resale
MULE 3010 TRANS 4 × 4
Utility Vehicle
Service Manual
All 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 Q uality Assurance D epartment/Consumer Products & Machinery
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 incurring 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., First Edition (1): Nov. 1, 2004 (M)
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LIST OF ABBREVIATIONS
A ampere(s) lb 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) ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
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EMISSION CONTROL INFORMATION
To protecttheenvironmentinwhich weall live, Kawasaki hasincorporated crankcase emission
(1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air 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 air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back 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 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.
The Clean Air A ct, 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 theultimate 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..."
(Continued on next page.)
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NOTE
The phrase "remove or render inoperative any device or e lement of design" has been generally
interpreted as f ollows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to p erform 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. Additionofcomponents or accessoriesthat resultin thevehicle exceedingthe 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 T HESE 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
(US Model only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective
intake and exhaust silencing systems. They are designed to give optimum performance while
maintaining a low noise level. Please do not remove these systems, or alter them in any way
which results in an increase in noise level.
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Foreword
This manual is designed primarily for use by
trained mechanics in aproperly equippedshop.
However, itcontains enoughdetail and basic in-
formationto makeit useful tothe owner who de-
siresto 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 and 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
beforestarting work, and then dothe work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use m akeshift
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
thisservicemanual. Any owner maintenanceor
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic M aintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Useproper tools and genuine Kawasaki Vehi-
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Special Tool
Catalog or Manual. Genuine parts provided
as spare parts are listed in the Parts Catalog.
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Remembertokeepcompleterecordsofmain-
tenance 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 m ake up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s 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 these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
additiontoWARNINGandCAUTION)whichwill
help you distinguish different types of informa-
tion.
NOTE
This note symbol ind icates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
done.
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
takebased onthe resultsof thetest orinspec-
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 partsrequire spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
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GENERAL INFORMATION 1-1
1
General Information
Table of Contents
Before Servicing..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Unit Conversion Table ............................................................................................................ 1-11
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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 n ote the following:
Battery Ground
Before completing any service on the vehicle, disconnect
thebattery wires fromthe batteryto prevent theengine from
accidentally turning over. Disconnect the ground wire (–)
first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive
(+) terminal of the battery then the negative (–) wire to the
negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
otherforeign materialsentering intosealed areasduring ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
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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.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limitson individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
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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.
Tightening 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 orhard 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, Lockin g 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.
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GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Donotremovepressedoilorgreasesealsunlessremoval
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before i nstalling
the seal.
Circlips, Cotter Pins
Replacecirclipsorcotterpinsthatwereremovedwithnew
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
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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-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the c rankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
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GENERAL INFORMATION 1-7
Model Identification
KAF620-J1 Left Side View
KAF620-J1 Right Side View
The KAF620-K1 is a camouflage-surface-treated model and identical to the K AF620-J1, the base
model, in every other aspect: controls, features, and specifications.
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1-8 GENERAL INFORMATION
General Specifications
Items KAF620-J1/K1
Dimensions
Overall Length 3 169 mm (124.76 in.)
Overall Width 1 449 mm (57.05 in.)
Overall Height 1 933 mm (76.10 in.)
Wheelbase 2 165 mm (85.24 in.)
Track:
Front 1 160 mm (45.67 in.)
Rear 1 180 mm (46.46 in.)
Ground Clearance 177 mm (6.97 in.)
Seat Height:
Front 868 mm (34.17 in.)
Rear 896 mm (35.28 in.)
Dry Weight
668 kg (1 473 lb)
Curb Weight:
Front
321 kg (708 lb)
Rear 374 kg (825 lb)
Fuel Tank Capacity 24.2 L (6.4 US gal)
Cargo Bed (L × W × H):
Long Bed 1 280 × 1 212 × 287 mm (50.39 × 47.72 × 11.30 in.)
Short Bed 770 × 1 212 × 287 mm (30.31 × 47.72 × 11.30 in.)
Performance
Maximum Torque 47 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm), (US)
Minimum Turning Radius 3.8 m (12.5 ft)
Engine
Type 4-stroke, OHV, 2 cylinder
Cooling System Liquid-cooled
Bore And Stroke 76 × 68 mm (2.99 × 2.68 in.)
Displacement 617 mL (37.6 cu in.)
Compression R atio 10.3
Carburetion System MIKUNI BW26-18
Starting System Electric Starter
Ignition System
Battery and transistor
Ignition Timing
3/900 13/2 000 18/2 500 23/3 500 (BTDC°/rpm)
Spark Plug NGK BPR2ES
Cylinder Numbering Method Front to rear, 1-2
Firing Order Front to rear, 1-2
Valve Timing:
Inlet:
open #1 68° BTDC/#2 64° BTDC
close #1 76° ABDC/#2 80° ABDC
duration 324°
Exhaust:
open 94° BBDC
close 48° ATDC
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GENERAL INFORMATION 1-9
General Specifications
Items KAF620-J1/K1
duration 322°
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Grade API SF or SG, API SH or SJ with JASO MA
Viscosity 10W-40
Capacity 1.8 L (1.9 US qt)
Coolant Capacity 4.6 L (4.9 US qt)
Drive Train
Primary Reduction System:
Type Belt drive torque converter
Reduction Ratio 3.9 0.85
Transmission Gear Ratio:
Forward:
High
1.821 (51/28)
Low
3.750 (51/28 × 25/20 × 28/17)
Reverse:
Low 4.220 (41/20 × 25/20 × 28/17)
Final Drive System:
Type
2-speed, automatic, reverse gear drive (4WD/2WD)
Reduction Ratio
5.4 (81/15)
Overall D rive Ratio:
Forward:
High 8.360
Low 17.212
Reverse:
Low 19.372
Front Final Gear Case Oil:
Type API GL-5 or GL-6 Hypoid gear oil for LSD
SAE 85W-140, SAE 90, or SAE 140
Capacity 0.4 L (0.4 US qt)
Transmission Oil:
Type API GL-5 Hypoid gear oil, SAE 90 (above 5°C, 41°F) or SAE
80 (below 5°C, 41°F)
Capacity 2.5 L (2.6 US qt)
Frame
Type Steel tube, Ladder
Caster (Rake Angle) 7.5°
Camber 0.8°
Trail 35 mm (1.4 in.)
Tire:
Front And Rear 23 × 11.00-10, Tubeless
Steering Type
Rack and pinion
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1-10 GENERAL INFORMATION
General Specifications
Items KAF620-J1/K1
Suspension:
Front:
Type MacPherson strut
Wheel Travel 100 mm (3.9 in.)
Rear:
Type De Dion axle
Wheel Travel 70 mm (2.8 in.)
Brake Type:
Front And Rear
Drum (Hydraulic)
Parking Brake Type Drum (Mechanical internal expansion)
Electrical Equipment
Battery 12 V 18 Ah
Headlight:
Type
Semi-sealed beam
Bulb 12 V 30 W × 2
Tail/Brake Light 12 V 5/21 W
Alternator:
Type Three - phase AC
Rated Output 21 A /12 V @3 000 rpm
Load Capacity
Maximum Vehicle Load
(Including Occupants And Cargo) 603 kg (1330 lb)
Maximum Cargo Bed Load:
Long 363 kg (800 lb)
Short 182 kg (401 lb)
US: United States Model
Specifications are subject to change without notice, and may not apply to every country.
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Kawasaki MULE 3010 TRANS 4 × 4 User manual

Category
Motorcycles
Type
User manual
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