Kawasaki Mule 1000 - Service Manual / Repair Manual

KAWASAKI MULE 1000 - SERVICE MANUAL

- English Service Manual to UTV Kawasaki Mule 1000.

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
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: