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2009-2013 Kawasaki Mule 4010 Trans Diesel 4x4 Service Manual

1. ie diem 7 9 ede 7 10 Osi REMOVA ideato ed tup E 7 10 Oll Purap Installations sii ret ra RE 7 10 OH UM O ISD CCU OM 7 10 Relef Pe ET ES 7 11 Relef 7 11 eoe ornata o RN Lol ced d bote ac 7 11 a LL LL A Dor 7 11 Pru 7 12 Oil Pressure 7 12 Oil Pressure SWNG UP 7 13 Oil Pressure Switch REMOV Al dota dota odd nci 7 13 Oil Pressure Switch Installation aa 7 13 TUE IN Tm 7 14 OM At ON hoe TM UE 7 14 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View 38 25 72 a 45 3 on 14 19 4 Oi Pan Bots and ns 78 oso enb 6
2. 2 35 Brake Hose and Pipe jnspection pp 2 35 Brake Hose and Pipe Replacement pp 2 36 de a mM M hcc bes 2 37 Brake Wheel Cylinder Assembly Replacement 2 38 Parking Brake Lever Inspection pp 2 40 2 2 PERIODIC MAINTENANCE vine Steering Inspection Steering Joint Dust Boot Inspection Seat Belt Inspection Electrical System Electrolyte Level Inspection Conventional Type Electrolyte Specific Gravity Inspection Conventional Type Battery Charging Condition Inspection Conventional Type Brake Light Switch Inspection General Lubrication Bolts Nuts and Fasteners Tightness Inspection 2 42 2 42 2 42 2 43 2 43 2 43 2 43 2 44 2 45 2 45 2 46 2 47 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected FREQUENCY Whichever First
3. 13 9 Brake HU 13 8 Brake Line AIF BIeediit tear ec ius dads 13 9 Brake Pedal Master 13 10 Brake Pedal Play el eri sciet Li 13 10 Master Cylinder TR ausa eauiesenes ene 13 10 Master Cylinder Installations qu te mut 13 10 Master Cylinder Disassembly Assembly pp 13 10 Master ylinder InspectlOli EE tai ui taut dele Pv t Ob eic 13 11 Brake Hoses and 13 12 Brake Hose and PINE InSpectlOfi nori ve nata Un Potuit eere n co 13 12 Brake Hose and Pipe 13 12 Brake 13 13 Brake Drum Removal OO D TRE 13 13 ded acude 13 13 da wan enees 13 14 Brake Panel Assemble Ssss iania onda clement 13 15 Brake Panel ASsSy c acie 13 15 Brake Panel ASSY InstallatloOn uoi od roo na et ao o adt o nd oec aoa 13 16 Brake Panel IDISASSCMDIY sida ade 13 16 Brake Panel Assembly L A EEA EE L L A EEEE E E rnn 13 18
4. Dni Conversion Fable poi oet 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 note the following Battery Ground Before completing any service on the vehicle disconnect the battery cables from the battery to prevent the engine from accidentally turning over Disconnect the ground cable first and then the positive When completed with the service first connect the positive cable to the positive terminal of the battery then the negative cable to the negative terminal Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 08020048 5 Solvent Use a high flash point solvent when cleaning parts High flash point solvent should be used according to directions of the solvent manufacturer Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering in
5. M M 3 29 Air Cleaner Element 3 29 Air Cleaner Housing REMOVAL pp 3 30 Air Cleaner Housing Installatiomn pp 3 30 Air Cleaner Housing Dust and or Water Inspection pp 3 30 wii EATEN TU E IU RU REPE 3 31 RSI 3 31 c EIE M IHE IM en EU 3 31 Fuel Filter Cartridge 3 31 Water Draining ER EET TET 3 31 3 32 T 3 32 Fuel Tank ber eue dun bae ted lue o Bea rut eda 3 33 Fuel us 3 35 Fuel Level Gauge Removal KAF950G9 3 36 Fuel Level Gauge Installation KAF950G9 3 37 Fuel Level Gauge Check KAF950G9 ener 3 37 Fuel Level Gauge Removal KAF950GD nennen nnn nnn n 3 37 Fuel Level Gauge Installation KAF950GD nne 3 38 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View c ae T eem AirCieaner Housing Mounting Bots 20 20 15 2 Ar Duct Mounting Bot 50 4mb 3 Approximately 60 4 Horizontal Line
6. inspect Note 24 General lubrication perform lubrication General lubrication perform 2 246 Bolts nuts and fasteners 2 47 inspect e Clean adjust lubricate torque or replace parts as necessary Service more frequently when operated mud dust or other harsh riding conditions Note 1 Conventional Type Battery PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean B Apply brake fluid EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide grease oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Part 5 Follow the specified tightening sequence SS Apply silicone sealant Fastener Nm kgfm fb Remarks Fuel System Air Cleaner Housing Mounting Bolts 20 2 0 15 Air Duct Mounting Bolt 5 0 0 51 44 in lb Air Vent Plug 5 0 0 51 44 in Ib Distributor Head Bolt 1 7 13 Fuel Filter Mounting Bolts 2 0 15 Fuel Injection Nozzles 6 0 44 Fuel Injection Pipe Clamp Bolts 0 75 65 Fuel Injection Pipe Mounting Nuts 2 5 18 Fuel Injection Pump Bracket Bolts 2 0 15 Fuel Injection Pump Gear Nu
7. 12 10 Front Final Gear Case Assembly 12 10 Differential Unit and Ring Gear Disassembly 12 11 Differential Unit and Ring Gear ASSembly 12 11 150 Clutch Torque Inspection 12 12 150 Clutch Plate Inspection 12 13 Pinion Gear Unit Disassembly 12 13 Pinion Gear Unit Assembly 12 13 Front Final Bevel Gear ecce cue 12 14 Backlash Adjustment 12 17 Tooth Contact Adjustment 12 18 Bevel Gear Inspection 12 21 Differential Gear Inspection 12 21 Tapered Roller Bearing ERES 12 21 Ball Bearing Inspection 12 21 Oil Seal Inspection 12 21 Bevel Gear 12 22 Bevel Gear Case Removal 12 22 Drive Shaft and Axles Bevel Gear Case Installation 12 22 Bevel Gear Case Disassembly 12 22 Bevel Gear Case Assembly 12 23 Drive Bevel Gear Removal 12 24 Drive Bevel Gear Installation 12 24 Bevel Gear Adjustment 12 25 Backlash Adjustment 12 25 Tooth Contact Adjustment 12 27 Bevel Gear Inspection 12 29 Ball Bearing Inspection 12 29 Oil Seal Inspection 12 29 Damper Inspection
8. 6 8 Air Cleaner Housing Installatiomn pp 6 9 Cleaner El ment REMOV Al meets ethos medals 6 9 Air Cleaner Element Cleaning Inspection 6 10 ORV GING T 6 11 Torque Converter Outer Cover Removal 444040 nennen nnns 6 11 Torque Converter Outer Cover Installation pp 6 11 Torque Converter Inner Cover 6 11 Torque Converter Inner Cover Installation 6 12 Torque Converter Gase eu aet inda dE et ues 6 12 Torque Converter Case 6 13 Torque Converter Case Disassembly pp 6 14 Torque Converter Case Assembly pp 6 14 DIVE 6 15 Dive Bet RE GO 6 15 datus 6 15 IVE UT IL MEER 6 15 Drive Belt Dellecuon InsDeclorsssise o 6 15 Drive Belt Deflection 6 15 Drive RUE YV CEU PT 6 16 DNVG me 6 16 Drive Pulley Disassembly siii 6 16 Dive Pulley InspeCcllQFll a dece a pedes pa vem obest us 6 17 Spider Shoe
9. n 2 S PURUS S Me 2 ENS gt E Bee NN LT Waa d a s 1008003 81 STEERING 15 29 EPS Electric Power Steering System EPS System Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Start the engine and check the EPS warning indicator light LED state Lights up 1 second and goes Lights up and does not go Does not light up off 3 off 6 Conduct non self diagnosis EPS svstem i 4X5 Conduct self di 12 system is normal 4 5 onduct self diagnosis Conduct general steering system inspection General Steering System oteering Wheel Steering Shaft Steering Gear Assembly Steering Knuckle etc NOTE 1 If the EPS warning indicator light LED does not light up even if the engine is started but the EPS motor is operating inspect the EPS warning indicator light LED 2 If the EPS warning indicator light LED does not light even if the engine is started and the EPS motor does not operate inspect the EPS ECU power source wiring ground wiring oil pressure switch and oil pressure warning indicator light 3 The EPS motor does not operate while the EPS warning indicator light LED lights up for 1second 4 If the steering wheel becomes too light while the vehicle is running inspect the speed sensor 5 When the vehicle is idling or low speed condition and if the st
10. eiit utet bx Los mua hose 9 23 Connecting Rod Big End Bearing Insert Crankpin Wear 9 23 Crankshaft Main Bearing Insert Journal Wear pp 9 24 ENG ici PNE ERE RS 9 25 PTT 9 25 End Pate SCAN AU OM m T ous 9 25 siur 9 27 Seal ee 9 27 Pistons and Clank CAS C5 ee 9 28 PISO REMOVA 9 28 mie a 9 28 Graakcase TeermoVala scetur tete ti DUM 9 29 SANK CASS Wai 9 29 Crankease ea 9 30 9 30 PISTON CVIINGEr CIGaF lle 9 31 CVIINGER BONING lt 9 31 Camshaft Bearing Replacement pp 9 31 Plug Replacement ats BP Qu od edes 9 32 Piston Ring arid Ring 2 9 32 ENG PE pP PETI E 9 33 F Iston fing ucc me n doe iced ea Ote ona loea 9 33 Piston and Piston Pin Wear Nt 9 33 9 2 CRANKSHAFT CRANKCASE Exploded View 110820098885 C CRANKSHAFT CRANKCASE 9 3 Expl
11. 12 29 Propeller Shafts 12 30 Propeller Shaft Removal 12 30 Propeller Shaft Installation 12 31 Propeller Shaft Bearing Housing 12 32 Propeller Shaft Bearing Housing Installation Propeller Shaft Inspection Front Axle Removal Front Axle Installation Rear Drive Shaft and Axle REMOVA m e M Rear Drive Shaft and Axle lnstallatlOD cssc tinto ess 12 35 Drive Shaft and Axle Inspection 12 35 Dust Boot Inspection 12 36 Front Axle Joint Boot Replacement 12 36 Ball Bearing Inspection 12 42 Grease Seal Inspection 12 43 12 2 FINAL DRIVE Exploded View FINAL DRIVE 12 3 Exploded View C2 Front Axe Cap Bos _ 090 73 Gear Case Brackets 48 32 74 Gear Case Mounting Nuts 44 48 32 S OlDanPug _ 29 20 15 GjOllerCap 29 30 2 77 Pinion Gear Bearing Housing Nus 25 28 18 78 PmonGearSioedNut me 120 87 0 MO 79 RmgGerBots 82 84 6t i _ 110 Ring Gear Cover Bots wid a 48 35 rit Ring Gear Cover Bots 8 25 28 18 G Apply grease HO Apply hypoid gear oil L Apply a non permanent locking agent M Apply molybdenum
12. 16 26 FEDO 16 27 Front Fender Removal 16 27 Front renderinstallauoli isi e a 16 27 Rear Fender Assembly Remova pp 16 27 COVEI 16 29 FOM COV RREMIOV Ali 16 29 FFONE COVER SO 16 29 Front Fender Inner Cover Removal pp 16 29 Front Fender Inner Cover Installation pp 16 30 Radiator Side Cover Removal en eu ED uiui o PO Ve 16 30 Cover deis a 16 30 Front side COVE esti estes ose duit tuU ULM UA ui 16 31 Rear Side Cover Removal 16 31 Rear Side Cover InstallallOIT tuat a 16 31 Middle Cover REMOVAl sed titu 16 31 16 32 REMOVA 16 32 16 2 FRAME Flap and Flap Slay tn e 16 32 Floor Center Panel Removals ecco e dx e NIMM NEN 16 32 Floor XGenterPanel INSTA AMON sett
13. 4 13 Thermostat a A Dui Oan 4 13 Thermostat spe colt 4 13 HOSES and I PE LSU eiue 4 14 Flose abd Pipe ItistallatlOli sueta oid x iia i Puch t ren er and vi 4 14 FIOSC INS mU 4 14 Radiator Fan Switch Coolant Temperature Switch pp 4 15 Radiator Fan Switch Removaliiusicescsiasecixi ex nur ab rr rt on Cor ea E Cr Cea ca 4 15 Coolant Temperature Switch Removal pp 4 15 Radiator Fan Switch Coolant Temperature Switch Installation 4 15 Ixadiator Tarowltch Inspe CON a eese cible i v vus ta estat m id vu oc dae etes i eus 4 15 Coolant Temperature Switch Inspection 4 15 4 2 COOLING SYSTEM Exploded View 1682017815 COOLING SYSTEM 4 3 Exploded View 1 Coolant Drain Pug 25 25 _ feens 78 3 Reser Tank Bat aimb 23 25 _ _ Radiator Screen Mounting Bolts Shroud Mounting Bolts 53 in Ib 0 1 n 15 Blue Marks Install the hoses so that their marks face upwards 16 KAF950G9 GA HA G Apply grease L Apply a non permanent locking agent R Replacement Parts 1 1 1 1 4 4 COOLING SYSTEM Specifications tem Standard Coolant Type Recommended Permanent type of antifreeze soft water and ethylene glycol plus corrosion
14. Slip Ring Diameter Carbon Brush Length Rectifier Inspection Regulator Inspection Alternator Ball Bearing Inspection Electric Starter System Starter Motor Remowval Starter Motor Installation Starter Motor Disassembly Starter Motor Assembly Carbon Brush Inspection Yoke Inspection Brush Plate Inspection Commutator Cleaning Inspection 17 4 17 12 17 14 17 16 17 18 17 20 17 21 17 23 17 24 17 24 17 25 17 25 17 25 17 27 17 27 17 27 17 27 17 29 17 30 17 31 17 33 17 33 17 33 17 33 17 35 17 36 17 37 17 37 17 37 17 37 17 37 17 38 17 38 17 38 17 40 17 40 17 40 17 40 17 42 17 43 17 43 17 44 17 44 Armature Inspection 17 44 Pinion Gear Inspection 17 45 Starter Switch Inspection 17 45 Starter Circuit Relay Inspection 17 45 Preheating System 17 47 Glow Plug Removal 17 47 Glow Plug Installation 17 47 Glow Plug Inspection 17 47 Preheating Timer Inspection 17 48 Glow Plug Relay Inspection 17 48 Glow Plug Relay Installation 17 48 Fuel Cut Solenoid 17 50 Fuel Cut Solenoi
15. er 8 5 ENGINE 0n NN RET T TM 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View P Engine Mounting Bots a 48 3 3 Stay Rod Rear 88 90 6 L Apply a non permanent locking agent 8 4 ENGINE REMOVAL INSTALLATION Special Tool Assembly Jig 57001 1566 5175 715665 ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Disconnect the battery cables see Battery Removal in the Electrical System chapter e Drain Engine Oil see Engine Oil and or Oil Filter Change in the Periodic Maintenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter ODrain the coolant from the cylinder head if necessary see Cylinder Head Removal in the Engine Top End chapter e Remove Cargo Bed see Cargo Bed Removal in the Frame chap ter Torque Converter Case see Torque Converter Case Re moval in the Converter System chapter e Disconnect Oil Pressure Switch Lead Connector A Glow Plug Lead B Coolant Temperature Switch Lead Connector C e Remove Water Hose D Fuel Hoses E Air Duct F see Fuel Pipe Removal in the Fuel System chapter e Remove Bracket Bolts A Engine Mount Stay B Throttle Cable End Rod C Fuel Cut Solenoid Lead Connector D e Remove Water Hose A Alternator Lead Connector B Alternator Ca
16. gt Removal Never drop the EPS ECU especially on a hard face Such a shock to the EPS ECU can damage it e Remove the band A and open the ECU cover B e Disconnect the EPS ECU connectors 15 48 STEERING EPS Electric Power Steering System e Remove Right Glove Compartment see Glove Compartment Re moval in the Frame chapter Screws A EPS ECU B with Cover e Remove the cover A from the EPS ECU EPS ECU Installation e Check that the rubber dampers A collars B and wellnut C are in place on the frame x If the rubber dampers are damaged or deteriorated re place them OWhen installing the rubber dampers note the following Olnstall the two rubber dampers of the front side so that the thin thickness side faces right side ODo not apply a soap and water solution or rubber lubri cant e Install the cover A on the EPS ECU Olnstall the cover so that open side faces left side e Insert the projections B of the EPS ECU to the rubber dampers C e Tighten the screws securely e When installing the band to the cover note the following OPass the band through four slits A of the cover OBind the cover with the band securely x If the EPS ECU was replaced be sure to register the EPS neutral position see EPS Neutral Position Registration NOTE OThe EPS system can not function until the neutral posi tion is registered in the new EP
17. the piston assembly two pistons by lightly tap the master cylinder on a wooden block Pistons C Springs D Secondary Cups E Primary Cups F Master Cylinder H OBe careful of the secondary cup direction I e Assemble the master cylinder OClean all the parts including the master cylinder with brake fluid or alcohol and apply brake fluid to the removed parts and the inner wall of the cylinder NOTICE Use only brake fluid isopropyl alcohol or ethyl al cohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline motor oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventu ally deteriorate the rubber used in the brake OPush the piston assembly in all the way with a screwdriver and install the piston stop bolt Use a new aluminum washer OTighten Torque Piston Stop Bolt 8 8 0 90 kgf m 78 in Ib Reservoir Clamp Bolt 6 1 N m 0 62 kgf m 54 e Install the master cylinder see Master Cylinder Installa tion in the Brakes chapter Brake Hose and Pipe Inspection e he high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace it if any cracks B or bulges C are noticed e he metal pipe will rust if
18. change smoothly according as the float moves up and down replace the fuel level gauge Fuel Level Gauge Resistance Standard Full position 9 11 Q Empty position 119 121 O Fuel Level Gauge Circuit KAF950GD 12119021842 1 Main Switch 2 Fuel Gauge 3 Fuel Level Gauge 4 Battery 5 Fuse Box 1 6 Main Fuse 30 A ELECTRICAL SYSTEM 17 57 Lighting System Headlight Beam Adjustment UEM e Turn the adjusting screw A each headlight or out WC to adjust the headlight vertically Headlight Bulb Replacement e Remove the front cover see Front Cover Removal in the Frame chapter e urn the headlight bulb A counterclockwise B and pull out the bulb from the headlight e Replace the headlight bulb e Fit the projections A of the bulb in the hollows B of the headlight e urn the headlight bulb A clockwise B e Install the front cover see Front Cover Installation in the Frame chapter Tail Brake Light Replacement e Remove Screws A Tail Brake Light Lens B 17 58 ELECTRICAL SYSTEM Lighting System e Push and turn the bulb A counterclockwise B and re move it NOTICE Do not use bulbs rated for greater wattage than the specified value e Insert the new bulb by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Install the tail brake light lens
19. KAF950G9 GC HA KAF950GD Starter Circuit Relay A Preheating Timer B Radiator Fan Relay C Glow Plug Relay D Parking Brake Light Switch E 17 22 ELECTRICAL SYSTEM Parts Location Fuse Box A Frame Ground Terminal B Radiator Fan Breaker C Battery 12 V 52 Ah D 50 A Fuse E Starter Motor Alternator B Glow Plugs C Coolant Temperature Switch D Engine Ground Terminal E Oil Pressure Switch A Fuel Cut Solenoid Valve B Neutral Switch C Horn A Radiator Fan Switch B Radiator Fan C Brake Light Switch D Speed Sensor A Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes in the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the main switch is ON or while the engine is running OBecause of the large amount of current never keep the main switch turned to the start position when the
20. 1 3 115 in Ib e Clean the surface of the sheaves with an oil less cleaning 2 HM fluid 6 22 CONVERTER SYSTEM Drive Pulley Bushing Installation e Press the cover bushing A into the cover B using the special tool so that the end of bushing is flush with the shoulder C in the hole Special Tool Bearing Driver Set 57001 1129 e Press the sheave bushing A into the movable sheave B using the special tool so that the end of bushing is flush with the shoulder C in the hole Special Tool Bearing Driver Set 57001 1129 Drive Pulley Installation e Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone and wipe off any oil with a clean cloth from the tapers Fixed Sheave Tapered Portion A Crankshaft Tapered Portion B A WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings e Install the drive pulley and screw in the drive pulley bolt with the stepped collar A and washers B as shown in the figure Bolt Head C e Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1548 e Tighten Torque Drive Pulley Bolt B 93 N m 9 5 kgf m 69 ft Ib IFG6008BS1 1706010851 1706007851 CONVERTER SYSTEM 6 23 Drive Pulley e Press the ramp weight bushing B from th
21. 4 2 4 4 mie Beg EET UT m 4 5 OO INE mU Tm 4 6 Coolant Level InispecllOhi s nds tete acd oin devra E deinde fax ote da abc vta 4 6 Coolant ID FANNING 4 6 COONAN FINA e I 4 6 Coolant Reserve Tank Removal 4 6 Coolant Reserve Tank Installation rci pco ark a a oe uid uerus 4 7 WV AUS MR 4 8 Water T Hgmpasermovalisn tino defe utu eds 4 8 Water Purp nstallatop sio vr tid hon i Deren 4 8 Water Pump InSbpSclolasii site delude UI Urine 4 9 Radiator and Radiator Faltas eot e S 4 10 E RUNE 4 10 Radiator Installator up ta Oca Chet CORR 4 11 Radiator Fam Removals i occas ce Scr mc em UR E aU 4 11 Radiator ten FU 4 11 Radiator INS DS CUO I asics 4 12 Radiator Cleaning UY 4 12 Radiator Cab let pecon MR RTT MEE 4 12 ELO 4 13 ES IMOV Al
22. 0 0 00000 B anngsand Ol mt eR ern ont concu BDall ibBeariadg Needle Bearing Inspection pp Oi OCCU A Transmission Sectoral FOU E ED tem 10 2 TRANSMISSION Exploded View 1J02058BW5 C TRANSMISSION 10 3 Exploded View 1 2WD AWD Shift Cable 2 Differential Shift Cable 3 White Tape G Apply grease R Replacement Parts 10 4 TRANSMISSION Exploded View 1J02042BW5 TRANSMISSION 10 5 Exploded View 1 Differential Gear Housing Bolts se 4 i 2 Shift Arm Positioning s8 zt 73 Shift Shaft Stop Bolts Sb G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts TO Apply transmission oil 10 6 TRANSMISSION Exploded View TRANSMISSION 10 7 Exploded View Po m9 sw se hmm Nm ftib 2 HiowGewCas Bots 20 20 18 _ 3 NewmaSwkh 1 t8 74 Transmission Gase Bos 88 090 75 Transmission Case Mounting Nus 44 48 32 R 6 Transmission Oi DrainPug 19 t8 G Apply grease LG Apply liquid gasket MO Apply molybdenum disulfide oil solution mix
23. Drive Pulley Bolt Drive Pulley Cover Bolts Driven Pulley Bolt Fan Cover Bolts Inner Cover Bolts Inner Cover Nut Ramp Weight Nuts Spider Wear Shoe Mounting Screws Engine Lubrication System Engine Cil Drain Plugs Oil Filter Stud Bolt Oil Nozzle Oil Pan Bolts and Nuts Oil Pressure Switch Oil Pump Drive Gear Bolt Oil Strainer Mounting Bolt and Nuts Relief Valve Bolt Engine Removal Installation Engine Mounting Bolts Stay Rod Rear Nut Crankshaft Crankcase Camshaft Drive Gear Bolt Camshaft Retainer Bolts Connecting Rod Cap Nuts Coolant Drain Plug 34 3 5 44 4 5 14 1 4 7 8 0 80 14 1 4 20 2 0 7 8 0 80 39 4 0 44 88 43 7 8 36 25 39 1 16 69 115 in Ib 69 78 in lb 39 1 16 78 116 R 61 in Ib R 203 10 in Ib L 10 69 in Ib 10 SS 15 69 29 32 65 32 69 in Ib 27 18 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Crankshaft Main Bearing Cap Bolts o9 6 0 44 Crankshaft Pulley Bolt 98 10 0 72 3 End Plate Bolts 39 4 0 29 Flywheel Mounting Bolts 44 4 5 32 5 Fuel Injection Pump Drive Gear Nut 64 6 5 47 Idle Gear Bolts 25 2 5 18 Oil Nozzle 14 1 4 10 Oil Pump Drive Gear Bolt 20 2 0 15 Oil Seal Retainer Bolts 5 4 0 55 48 1 Timing Gear Case Bolts 7 8 0 80 69 1 1 Timing Gear Case Cover Bolts 7 8 0 80 69 in Ib Transmission Bearing Holder 118 12 0 87 0 Differential Gear Housing Bolts 57 5 8 42 L Hi Low Gear Case Bolts 20 2 0 15 Neu
24. Retighten hose joint section fuel cartridge drain cap and vent plug Replace or retighten within specified value Drain water from fuel filter and tank Defective fuel injection nozzle Adjust injection timing 15120018 3 24 FUEL SYSTEM Fuel Injection Pump Troubleshooting Engine Stalling i i C t start Check to see if engine can start An MOESIA inder rue Starting Can restart Unstable Check to see if idling is stable See section under Unstable Idling Stable Check to see if idling speed No good Adjust idling speed conforms to specification Good No good Voltage is applied Defective fuel cut solenoid Check to see if fuel cut With main switch turned ON solenoid is functioning check to see if voltage is applied properly to fuel cut solenoid No voltage is applied 1 Defective fuse 2 Defective main switch Good No good 1 Air is sucked or fuel is Check to see if pump is full of fuel leaking from fuel inlet hose joint section and fuel filter Good 2 Fuel filter clogged No good Drain water from fuel filter and tank Check to see if fuel filter is contained water Good Malfunctioning injection pump 15120028 Fuel Injection Pump Troubleshooting Lack of Power Check to see if fuel filter is restricted Good Check to see if throttle cable is adjusted properly Good Check to see if overflow screw out an
25. non adjustable 0 20 mm 0 0 79 in at 1G 23 x 11 00 10 DUNLOP KT869 Tubeless DURO DK 968 Tubeless 97 kPa 1 0 kgf cm 14 psi 167 kPa 1 7 kgf cm 24 psi 250 kPa 2 5 kgf cm 36 psi 13 2 mm 0 52 in 3 mm 0 12 in Wheel Alignment Toe in is the amount that the front wheels are closer to gether in front than at the rear at the axle height When there is toe in the distance A rear is greater than B front as shown in the figure 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 If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are built in and require no adjustment A Rear B Front Amount of Toe in Distance A and B are measured at hub height Toe in Adjustment e Lift the front wheels off the ground e Apply a heavy coat of chalk near the center of the front tires e Using a needle nose scriber make a thin mark near the center of the chalk coating while turning the wheel e Set the wheels so that the marks on the tires are at the front side and at the level of the axle height e Ground the front wheels e Set the steering wheel straight ahead e At the level of the axle height measure the distance be tween the scribed lines with a measure e Move the vehicle rearward until the marks
26. 12 38 FINAL DRIVE Drive Shaft and Axles e Pinch the small boot band A with a suitable tool B to install it e Compress the axle assembly to the specified length while relieving the air pressure inside the boot e Hold the axle at this setting Standard Length of Assembling Outboard 254 5 mm 10 020 in A 1107015 81 OSlightly open A the larger diameter end of the joint boot to equalize the air pressure inside the boot e Pinch the boot bands A with a suitable tool B to install it OCompress the suitable tool with a vice if necessary e Be sure outside diameter of the band A is less than the maximum diameter Maximum Outside Diameter of Band 75 9 mm 2 99 in FINAL DRIVE 12 39 Drive Shaft and Axles Inboard Joint Boot Removal e Remove Front Axle see Front Axle Removal Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove Collar C Cap D e Remove Front Axle see Front Axle Removal e ap the joint portion of the bands A with a suitable tool e Scrap the removed boot bands e Slide the joint boot B toward the outboard joint e Remove the retaining ring A e Separate the bearing cup from the axle shaft e Remove the steel balls A e Slide the cage B toward the outboard joint e Remove Circlip A Special Tool Outside Circlip Pliers B 57001 144 12 40 FINAL DRIVE Drive Shaft and Axles e Remove Inner
27. 5 24 ENGINE TOP END Exhaust Pipe and Muffler Exhaust Pipe and Muffler Installation e Installation is the reverse of removal note the following e Tighten Torque Muffler Mounting Bolts 20 2 0 kgf m 15 ft Ib e Apply a non permanent locking agent to the threads of the muffler mounting bolts e Replace the exhaust pipe gasket and muffler connecting gasket with new ones e After installation thoroughly warm up the engine wait un til the engine cools down retighten all the bolts and nuts Exhaust Pipe and Muffler Inspection e Before removing check for signs of leakage at the ex haust pipe gasket in the cylinder head and at the muffler joint x If there are signs of leakage around the exhaust pipe gas ket it should be replaced If the muffler to exhaust pipe joint leaks tighten the joint bolts e Check the exhaust pipe and muffler for dents cracks rust and holes If the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise Spark Arrester Cleaning e Refer to the Spark Arrester Cleaning in the Periodic Main tenance chapter CONVERTER SYSTEM 6 1 Converter System Table of Contents EXDIOGEG VIEW c 6 2 AOI 6 6 Special T UMSO 6 7 AIC essei tete metu tx tbe slip a amo dob dir dua itn omn Dr acu tuU re addam trm 6 8 Air Cleaner Housing
28. Brake Wheel Cylinder Assembly Replacement Front Brake Panel e Remove the brake drum see Brake Drum Removal in the Brakes chapter OThe left front brake panel is shown e Remove the brake shoe springs A and brake shoes B individually OPush the shoe hold down springs C and twist the pins D to remove the shoes NOTE OWrap the brake shoes with a clean cloth to protect the linings from grease or dirt e Remove the brake pipe nipple A and plug the nipple Olmmediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Unscrew the mounting bolts B and take off C the front brake wheel cylinder Rear Brake Panel e Remove the brake shoes A in the same way as in the front brake panel Rear Brake Wheel Cylinder B Rear Brake Panel e Remove the brake pipe nipple A and plug the nipple e Unscrew the mounting nuts B and take off C the rear brake wheel cylinder Front D Misio P PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Replace the rear wheel cylinder with a new one e Set the brake shoe clearance adjuster so that the drum can be reinstalled on the panel assembly Front Brake Panel OTurn A either end of the cylinder fully while holding the other end B Both ends are put into the cylinder Rear Brake Panel OPush the ratchet A forwards and in to r
29. CD co OF L eau BR OTD b A 08 16 B ELECTRICAL SYSTEM 17 61 gt R 6 BK W BK W BK W er V 78 BR pp 7 1913015884 C Oil Pressure Switch EPS Fuse 7 5 A EPS Warning Indicator Light LED EPS ECU Reverse Light Switch EUR Model Reverse Light EUR Model Tail Brake Lights Battery Main Fuse 30 A Fuse Box 2 17 62 ELECTRICAL SYSTEM Switches and Sensors Brake Light Switch Inspection e Refer to the Brake Light Switch Inspection in the Periodic Maintenance chapter Radiator Fan Switch Inspection e Remove the radiator fan switch see Radiator Fan Switch Removal in the Cooling System chapter e Suspend the fan switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant so that the sensitive portions C are located in almost the same depth NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table Special Tool Hand Tester 57001 139
30. ELECTRICAL SYSTEM 17 63 GP180203532 17 64 ELECTRICAL SYSTEM Switches and Sensors Switch Inspection e Using a hand tester check to see that only con nections shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 OFor the main switch light switch brake light switch park ing brake light switch and neutral switch refer to the ta bles in the Wiring Diagram x If the switch has an open or short repair it or replace it with a new one Horn Switch Connections Sd a 9 9 Ren Pressure Switch Connections engine is stones engine te running Engine lubrication system is in good condition Reverse Light Switch Connections EUR Model Speed Sensor Removal NOTICE Never drop the speed sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the transmission oil see Transmission Oil Change in the Periodic Maintenance chapter e Disconnect the speed sensor lead connector A e Remove Bolt B Speed Sensor C ELECTRICAL SYSTEM 17 65 Switches and Sensors Speed Sensor Installation e Replace the O ring A with a new one e Apply transmission oil to the O ring e Tighten Torque Speed Senor Bolt 8 8 0 90 kgf m 78 in Ib Speed Sensor Inspection e Remove the speed sensor see Speed Sensor Removal e Connect the speed sensor connector A wit
31. Injection Timing Plunger Stroke Marking of Injection Nozzle Red or Green 0 81 0 03 mm 0 0319 0 0012 in None 0 81 0 02 mm 0 0319 0 0008 in x If the indicator reading is not within the specification re peat the procedure e Remove the dial gauge adapter and dial gauge e Install the distributor head bolt and washer e Tighten Torque Distributor Head Bolt 17 N m 1 7 kgf m 13 ft Ib FUEL SYSTEM 3 21 Fuel Injection Pump Fuel Injection Pump Inspection and Repair NOTE ODo not disassemble the fuel injection pump and injec tion nozzles The pump and nozzles are produced in highly automated modern production facilities They cannot be assembled by hand in the field e Refer to the troubleshooting section to check of the pump x If the pump and nozzle are malfunction replace them or consult a reliable repair shop ex Denso Service Station 3 22 FUEL SYSTEM Fuel Injection Pump Troubleshooting Hard Starting Check to see if fuel is injected from injection pipe Loosen the injection pipe nuts at the top of the injection nozzles Fuel is injected No good No fuel Check to see if preheating Check following parts injection system is functioning 1 Glow plug relay properly 2 Preheating timer Good No good Check to see if glow plug is Defective glow plug functioning properly Good No good Check to see if injection Adjust injection timing timing is proper Good No good Check
32. Joint To Clamp on Center Bar To Hole in Floor Board From Fuel Tank To Injection Pump From Injection Pump To Fuel Tank Harness and Leads Brake Pipe All Cables Position the tabs of clamps facing toward backside of vehicle Section A A Pass the fuel hose through clamp APPENDIX 18 27 18 28 APPENDIX Cable Wire and Hose Routing KAF950G9 GC HA 18080828484 1 Horn Button 2 Horn Switch Contact 3 Run the born switch lead to the straightly down Do not twist it around the steering shaft 4 Ground Lead 5 To Main Harness 6 Band 7 Front 8 Installation condition of horn switch contact 9 View from A APPENDIX 18 29 Cable Wire and Hose Routing 1B08024BWN4 1 Differential Shift Cable 2 Cable Bracket 3 About 100 mm 3 94 in 4 Cable Clamp 5 2WD AWD Shift Cable 18 30 APPENDIX Cable Wire and Hose Routing EUR Model Tail Brake Light Lead Clearance 1 2 mm 0 04 0 08 in Band Neutral Switch Shift Lever Reverse Switch Switch Holder a mB WN Adjust the switch location to this clear ance in shift lever working condition 18080988844 C Tail Brake Light Reverse Light Bracket Cargo Bed Cap Bracket View A View B Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed lt is meant simply as a rough guide to a
33. Nuts FINAL DRIVE 12 31 12 32 FINAL DRIVE Propeller Shafts T 8 3 5 b Hl 4554224 p Pee Pate gt ni Mr zr NAT UN bp Pete 4412 11096008887 Propeller Shaft Bearing Housing Removal e Remove Front Propeller Shaft see Propeller Shaft Removal Propeller Shaft Bearing Housing Cover Bolts A Both Sides Propeller Shaft Bearing Housing Covers B Both Sides e Wipe off the grease e Remove Stop Screws A Front Propeller Shaft B Propeller Shaft Bearing Housing C FINAL DRIVE 12 33 Propeller Shafts e Wipe off the grease e Remove the circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the propeller shaft bearing housing cover B y E EU sf eee Propeller Shaft Bearing Housing Installation e Clean the front propeller shaft by wiping off the used grease on it e Install Propeller Shaft Bearing Housing Cover A New Circlip Special Tool Outside Circlip Pliers 57001 144 e Insert the front propeller shaft in the propeller shaft bear ing housing B e Tighten Torque Stop Screws 3 9 N m 0 40 kgf m 35 e Apply grease about 8 g 0 28 oz C into each cover e Install Propeller Shaft Bearing Housing Covers A Propeller Shaft Bearing Housing Cover Bolts B Both Sides e Tighten Torque Propeller Sha
34. PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Bleed the air from the cooling system as follows OStart the engine and run it until no more air bubbles A can be seen in the coolant less than five minutes OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the filler neck e Install the radiator cap ower the front wheels slowly e Fill the reserve tank up to the F full level line A with coolant NOTICE Do not add more coolant above the F full level line e Install the reserve tank cap B Cooling Fan Belt Inspection e ilt up the cargo bed e Remove Rear Propeller Shaft see Propeller Shaft Removal in the Final Drive chapter Water Pipe A and Water Hose B e Remove the fan cover bolts A e Take off the fan cover e Rotate the fan blade B and position it as shown in the figure EM gt eS 2662 29 6005010951 SW M UP d 5008019 F 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the fan cover A as shown in the figure e Remove Fan Mounting Bolts A Cooling Fan B Spacer e Reinstall the spacer A and tighten the fan mounting bolts B temporary Torque Fan Mounting Bolts 8 8 0 90 kgf m 78 in Ib e Remove Bolts A Fan Belt Cover B e Check the cooling fan belt A for excessive wear crack or broken
35. e Remove Front Cargo Compartment see Front Cargo Compart ment Removal in the Frame chapter Universal Joint Clamp Bolt A Steering Wheel and Main Shaft Assembly e Remove Steering Shaft Mounting Bolts Washers and Nuts A Steering Shaft B e Remove Clamp Bolt A Intermediate Shaft B Steering Wheel and Steering Shaft Installation KAF950GD e Apply grease to the dust cover lips A e Install the steering shaft A to the upper universal joint B e Install the universal joint clamp bolt C while aligning the notch on the steering shaft with the clamp bolt hole on the upper universal joint and tighten it temporary e Replace the steering shaft mounting nuts F with new ones e Install the steering shaft mounting bolts D washers E and nuts e Tighten Torque Universal Joint Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib STEERING 15 11 1004004 81 15 12 STEERING Steering Wheel and Main Shaft Assembly e Install the washer e Mount the steering wheel on the steering shaft temporar e Adjust the following items Steering Wheel Position see Steering Wheel Position Adjustment Steering Wheel Centering see Steering Wheel Center ing e Replace the steering wheel mounting nut with a new one e Tighten Torque Steering Wheel Mounting Nut 52 5 3 38 ft lb e Insert the hook portions A into the holes B of the steer ing wheel STEERING 15 13
36. e Slowly depress the tester lever until the pressure reaches about 11 768 kPa 120 kgf cm 1 706 psi When there is no mark on the nozzle e Slowly depress the tester lever until the pressure reaches about 12 749 kPa 130 kgf cm 1 849 psi Checking for Buzzing and Spray Pattern e Operate the tester lever at a rate of 30 to 60 strokes per minute in the case of a new nozzle 15 to 60 strokes per minute in the case of a used nozzle e Make sure that buzzing occurs during these strokes NOTE OWhen this buzzing occurs can feel a pulsation transmitted to your hand through the nozzle tester han dle while the nozzle injection is taking place OWhen the pressurized fuel from the injection pump is in Jected this injection is accompanied by rapid recurring pressure variations during the time from the start to the finish of the injection These pulsing pressure variations are felt as buzzing OThese pulsations of the fuel are affected mainly by the movement of the nozzle needle and good or bad condi tions of the valve seat section OGenerally a nozzle that buzzes is good because a spray condition where intermittent pulsations are gen erated assures good cut off of the fuel supply FUEL SYSTEM 3 13 Good Bad 3 14 FUEL SYSTEM Fuel Injection Nozzle e Ensure that the fuel spray forms a cone shape while the buzzing is occurring and that the center of the cone is aligned with the cen
37. spacer thickness equals about 1 4 mm 0 055 in change in belt deflection x If the belt deflection is less than 28 mm 1 10 in add the spacers B to increase it OThe rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 6 mm 0 063 in change in belt deflection 1 07020 81 Spacers Thickness ParNo 0 3 mm 0 012 in 0 6 mm 0 024 in 0 8 mm 0 031 in 1 0 mm 0 039 in 1 4 mm 0 055 in e Assemble the driven pulley see Driven Pulley Assembly in the Converter System chapter e With the transmission in neutral rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection e Measure the belt deflection again and repeat the above procedures until it is within the standard range eUsing the flywheel amp pulley holder apply a non permanent locking agent to the driven pulley bolt and tighten it Special Tool Flywheel amp Pulley Holder 57001 1605 Torque Driven Pulley Bolt 93 9 5 kgf m 69 ft Ib Converter Driven Pulley Shoe Inspection e Disassemble the driven pulley see Driven Pulley Disas sembly in the Converter System chapter cams A of ramp B or the wear shoes C are dam aged or worn replace the ramp or the wear shoes 17070117851 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If the wear shoe contact area width A is greater than service lim
38. the lead is defective Re place the lead or the wiring harness if necessary A 22 ae E PAS Nip 2 e S td aa a dr em 1007010251 ELECTRICAL SYSTEM 17 25 Battery Oln this model two batteries are prepared Conventional Type Battery A KAF950G9 GC HA Other Than US Model The caps B can be removed Sealed Type Battery A US Model and KAF950GD Battery Removal e ilt up the front seat e Remove the front seat lower cover rear see Floor Center Panel Removal in the Frame chapter e Slide the positive terminal cover A out e Disconnect the battery negative cable and lead B first and then the positive cable and leads C e Remove Battery Holder Mounting Nuts D Battery Holder E e Remove the battery backward Battery Installation e Check that the rubber dampers A on the battery case B and battery holder C are properly in place Olnstall the battery case A so that the long side B faces right side C 17 26 ELECTRICAL SYSTEM Battery e Install the O rings A from the opposite end of the threads B of each battery holder rod C to protect the O rings NOTE ODo not set the O ring on the threads of the rod e Install Battery Holder Rod Front Side Pipe A For Conventional Type Battery 206 5 mm 8 13 in For Sealed Type Battery 199 5 mm 7 85 in Battery Holder B
39. 0 044 mm 0 0008 0 0017 in Service Limit 0 07 mm 0 0028 in x If the clearance exceeds the service limit replace the bearing insert e Repeat the procedure for the other connecting rods 9 24 CRANKSHAFT CRANKCASE Crankshaft and Connecting Rods Crankshaft Main Bearing Insert Journal Wear e Using plastigage press gauge A measure the bearing insert journal clearance NOTE OTighten the crankshaft main bearing cap bolts to the specified torque see Crankshaft Installation ODo not turn the crankshaft during clearance measure ment Crankshaft Main Bearing Insert Journal Clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 07 mm 0 0028 in xIf the clearance exceeds the service limit replace the bearing insert e Repeat the procedure for the other main bearings CRANKSHAFT CRANKCASE 9 25 End Plate End Plate Removal e Remove Torque Converter Case see Torque Converter Case Re moval in the Converter System chapter Stud Bolt A e Using the flywheel holder A hold the flywheel Special Tool Flywheel Holder 57001 1438 e Remove Flywheel Mounting Bolts B Coupling C Flywheel D e Remove Bolts A Engine Mount Stay B Bolts C Cil Level Gauge Pipe D Bolt E e Remove End Plate Seal Cover A End Plate Bolts B Plate C Starter Motor Mounting Bolts D End Plate E End Plate Installation e Remove the old sealant and clean around the oil se
40. 4 Wiper 358004 Warning Light EPS 6 Cargo Bed Light gt xt G o uu Fuse tok 5 40 tn m e 69 x 1 EPS ECU Relay Diodes 5 e ex 1 1 1 Dr 1 1 1 25 e 1 gt Ja r5 Fuse zx m 7 EPS Motor EPS Torque EPS R Y T9 Sensor Self diagnosis System Speed jj Connector Sensor SYSTEM 17 15 for Example Starter Circuit Relay l l BK W R W Europe Model i HILL BK Y BL R BK Y Injection Le x m Pump NN Glow Plug Relay Fuse Box 1 m KIM Fusible 9 Link 50A Fuse Box 2 0 BK W 55 5 Fuse Box 1 x 1 ns 1 Starter Relay Fuse 30 ot 3 2 ccessory Conector Fuse 20 Preheating Starter 3 Accessory Fuse 20 Timer Motor 2 puse BOX 2 011 Coolant 1 Fuse 30A PressureTemperature 2 Horn Fuse Switch Switch 3 Preheating Timer Fuse NEUTRAL SWITCH CONNECTIONS Terminal Ground BRAKE LIGHT SWITCH CONNECTIONS PARKING BRAKE LIGHT SWITCH CONNECTIONS pour Terminal Ground hen parking brake lever is pulled up om ERE Neutral N Position Cam 98052 0544B When brake pedal is pushed down 01 ELS 8 O8 12V21 58X2 b Brake Tail Lights Neutral Sw
41. Coolant Temperature Switch Inspection e Refer to the Coolant Temperature Switch Inspection in the Electrical System chapter ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded M 5 2 SDS CINCAUONS 5 4 Seglal MERERETUR mm 5 5 TC Cic ael died been terat iui E EM ELE 5 7 Cylinder Compression Measurement enean nnns 5 7 Cyliider Mead REMOVA elec 5 7 GCylibderTeacd Installallore deco hdi Odd tt mo doe ini be 5 8 Cylinder Head Wal souci dle 5 9 ROCK EN 555 5 10 Rocker Arm Components Remioval nnns 5 10 Rocker Arm Components Installation 5 10 Rocker Arm Components Disassembly 5 11 Rocker Arm Components Assembly pp 5 11 Cup ee a 5 11 T MT 5 13 Liter 5 13 Valve ISO 5 13 Valve Tuscan Fa Ca Pere sd 5 13 VAI a ta rosa nt E
42. Cylinder Head Bolts 34 N m 3 5 kgf m 25 959724 LL e Apply engine oil and install the rocker arm push rods A in original locations if reused OFace the recessed end B upward 04000 81 e Install Valve Stem Caps Rocker Arm Components see Rocker Arm Components Installation e Inspect the valve clearance see Valve Clearance Inspec tion in the Periodic Maintenance chapter e nstall the removed parts see appropriate chapters Cylinder Head Warp e Clean the cylinder head e L ay a straightedge A across the lower surface inlet and exhaust manifold mounting surface of the head at several different points and measure warp by inserting a thick ness gauge B between the straightedge and the head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 1 mm 0 004 in 5 10 ENGINE TOP END Rocker Shaft and Rocker Arm Rocker Arm Components Removal e Remove Fan Belt Cover see Cooling Fan Belt Inspection in the Periodic Maintenance chapter Breather Hose A Cylinder Head Cover Bolts B and Washers C Cylinder Head Cover D e Turn the crankshaft pulley A clockwise so that the timing mark B on the pulley aligns with the reference point C on the timing cover OCheck that the rocker arms at 1 cylinder are free xf not turn th
43. MULE 4010 54 4 DIESEL Kawasaki m reed pes rama eater tre t am zm 85 mm aa aa UC m h j P Utility Vehicle Service Manual 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 Periodic Maintenance Fuel System Cooling System Engine Top End Converter System Engine Lubrication System Engine Removal Installation Crankshaft Crankcase Transmission Wheels Tires Final Drive Brakes Suspension Electrical System co N gt Appendix MULE 4010 54 4 Kawasaki DIESEL 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 Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepte
44. OBe careful not to overtighten the lens mounting screws Light Switch Bulb Replacement e Remove the front cargo compartment see Front Cargo Compartment Removal in the Frame chapter e Turn the socket A counterclockwise and pull it with the bulb e Pull the bulb A out of the socket NOTICE Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Insert the new bulb in the socket e Align the projections A of the socket with the recesses B in the switch body and turn the socket clockwise ELECTRICAL SYSTEM 17 59 Lighting System Indicator Light Bulb Replacement Oil Pressure Warning Indicator Light A Coolant Temperature Warning Indicator Light B Parking Brake Indicator Light C Glow Plug Light D e Remove Light Assembly A Lens B e Roll the rubber A up and pull the bulb B out of the socket NOTICE Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Install New Bulb Lens A Light Assembly B Speedometer Illumination Bulb Replacement e Remove the front cargo compartment see Front Cargo Compartment Removal in the Frame chapter e Pull the socket A with the bulb from the speedometer 17 60 ELECTRICAL SYSTEM Lighting System e Pull the bulb A out of the socket B NOTICE Do no
45. Regular Service Service Throttle pedal play inspect EN Idle speed adjust EM Fuel filter element replace Fuel filter water drain i l Coolant change Radiator clean Radiator hoses and connections inspect 1 year 2 18 o 0 Converter drive belt deflection 2 26 Inspect Converter driven pulley shoe 2 7 inspect Converter air cleaner element 2 28 clean Engine oil change Oil filter replace e Clean adjust lubricate torque or replace parts as necessary Service more frequently when operated in mud dust or other harsh riding conditions 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart oee Page OPERATION CHASSIS TSS Front final gear case oil and 2 30 transmission case oil y 2 31 Wheel nuts tightness inspect nuts Wheel nuts tightness inspect inspect 2 2 31 a Brake fuidlevel inspect e 2 Brake fuid change 2 Brake pedal play inspect 29 Brake master cylinder cup and dust 2 years 2 35 seal replace hose andpipe inepect 2 gm Brakewear inspec wear Brakewear inspect 2 2 37 Parking brake lever inspect lever inspect MuR 1 tai t 2 240 FSteering inspect 24 Steering joint dust boots inspect e e _ 22
46. Shifter Groove B Dogs on Drive Bevel Gear Shaft C Shifter Block D If they are damaged or worn excessively replace them e Replace parts worn beyond the service limit Shifter Block Outside Diameter Standard 13 95 14 00 mm 0 549 0 551 in Service Limit 13 8 mm 0 543 in Shifter Groove Width Standard 14 0 14 2 mm 0 551 0 559 in Service Limit 14 3 mm 0 563 in TRANSMISSION 10 29 Differential Gears and Shift Mechanism Differential Shift Cable Adjustment e Put the shift lever A in the UNLOCK position e Set the shift shaft lever A in the UNLOCK position e oosen the adjuster nut B until the inner cable is slightly loosened e Tighten the adjuster nut C securely Differential Shift Cable Lubrication Whenever the shift cable is removed lubricate the cable as follows e Apply a thin coating of grease to the cable ends Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber 6604011451 Differential Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely A within the cable housing x the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable Differential Shift Mechanism Removal e Remove Drive Shafts and Axles see Rear Drive Shaft and Axle Removal in the Final Drive chapter Shift Shaft Stop Bolt A Shift Shaft Lever Mounting Nut B Shift Shaft Lever
47. Terminal Ground BRAKE LIGHT SWITCH CONNECTIONS PARKING BRAKE LIGHT SWITCH CONNECTIONS pour Terminal Ground hen parking brake lever is pulled up ocm Neutral N Position Cm 98052 07564 When brake pedal is pushed down 01 ELS 8 O8 12V21 58X2 b Brake Tail Lights Neutral Switch Color Code Black Brown Green GY Gray LB Light Blue LG Light Green 0 Orange P Pink PU Purple Red W White Yellow W2R0756AWS5 17 18 ELECTRICAL SYSTEM Specifications tem _ Standard Battery Capacity 12V 52 Ah Voltage 12 6 V or more Conventional Type Gross Weight 14 5 kg 32 0 Ib Electrolyte Volume 3 8 L 232 cu in Electrolyte Level Between upper and lower level Specific Gravity 1 265 at 20 C 68 F Eris Sealed Type Gross Weight 13 4 kg 29 5 Ib Electrolyte Volume 3 03 L 185 cu in Alternator Type Three phase built in regulator rectifier Fan Belt Deflection 9 5 11 5 mm 0 37 0 45 in at 98 10 kgf 22 Ib Output Voltage 13 3 14 8 V at 25 C 77 F Output Amperage no load 10 A or less Output Amperage load 20 A or more Stator Coil Resistance 0 2 O or less Rotor Coil Resistance 2 8 3 00 Slip Ring Diameter 14 4 mm 0 5 in 14 0 mm 0 55 in Carbon Brush
48. e Remove Screws A and Collars Quick Rivets B Flap Cover C Flap and Flap Stay Removal e Remove Rear Side Cover see Rear Side Cover Removal Flap Cover see Flap Cover Removal Screw A and Collar Quick Rivet B Flap C e Remove Flap Stay Mounting Bolts A Flap Stay B Floor Center Panel Removal e Remove Screws A Quick Rivets B Front Seat Lower Cover Front C 8 FRAME 16 33 Covers e Remove Bolts A Throttle Pedal B e Remove Tapping Screws A Front Floor Center Panel B e Remove Tapping Screws A Front Seat Lower Cover Rear B e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Tapping Screws A Tapping Screw B and Washer Rear Seat Lower Cover C e Remove Tapping Screws A Rear Floor Center Panel B 16 34 FRAME Covers Floor Center Panel Installation e Installation is the reverse of removal note the following Olnstall the bushing A so that the cut side B faces to the throttle pedal Rear End Subframe Rear End Subframe Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Transmission Case see Transmission Case Removal in the Transmission chapter Rear End Subframe Mounting Bolts A and Nuts Rear End Subframe B Rear End Subframe Installation e Replace the rear end subframe mounting nuts with new ones e Tighten Torque Rear End Subframe Mounting Nu
49. x If necessary replace the belt with a new one PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Check the fan belt deflection OUse a ruler A push the belt with 98 N 10 kgf 22 Ib force Push Gauge B Fan Belt Deflection Standard 9 5 11 5 mm 0 37 0 45 in x If the deflection is incorrect adjust it e oosen the alternator adjusting bracket bolt A and alter nator mounting bolt B Alternator C e Adjust the fan belt deflection OUse a ruler push the belt with 98 N 10 kgf 22 Ib force e Tighten the bolts Torque Alternator Adjusting Bracket Bolts 20 N m 2 0 15 16 Alternator Mounting Bolt 39 N m 4 0 kgf m 29 ft Ib e When installing the water pipe and water hose note the following OCheck that the damper A is in place on the water pipe B Air Bleed Bolt C 5 10 mm 0 20 0 40 in D x If the damper is damaged or deteriorated replace it 1306008851 Olnsert the water pipe A up to the end of the bending radius of the water hose B as shown in the figure Air Bleed Bolt C OMake sure that there is clearance between the water pipe and the fan cover 1306007851 Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked when the engine is cold at room temperature e Remove Fan Belt Cover see Cooling Fan Belt Inspection Cylinder Head Cover see Rocker Arm Components Re moval in the Engine Top End chapter
50. 0 0028 in 0 08 mm 0 0031 in Crankcase Height 238 70 239 30 mm 238 60 mm 9 3976 9 4212 in 9 3937 in Cylinder Inside Diameter 72 00 72 03 mm 72 105 mm 2 8346 2 8358 in 2 8388 in or more than 0 035 mm 0 0014 in Valve Lifter Bore Inside Diameter Camshaft Bearing Inside Diameter Piston Diameter Piston Cylinder Clearance 18 018 mm 0 7094 in 71 93 71 96 mm 2 8319 2 8331 in 0 06 0 08 mm 0 0024 0 0031 in difference between any two measurements 18 05 mm 0 7106 in 36 06 mm 1 4197 in 0 12 mm 0 0047 in Oversize Piston and Rings 0 25 mm 0 0098 in Oversize Piston Ring Groove Clearance less than 0 12 mm Top Second and Oil Ring 0 0047 in Piston Ring End Gap 0 70 mm 0 0276 in Top Second and Oil Ring Piston Ring Thickness Top 1 445 1 465 mm i 0 0569 0 0577 in Second 1 470 1 490 mm Ed ictus 0 0579 0 0587 in Oil 2 970 2 990 mm 0 1169 0 1177 in Piston Pin Bore Diameter 18 03 mm 0 7098 in Piston Pin Diameter 17 98 mm 0 7079 in 9 6 CRANKSHAFT CRANKCASE Special Tools Bearing Puller Adapter Crankcase Splitting Tool Assembly 57001 136 57001 1098 875701365 875710888 Inside Circlip Pliers Camshaft Bearing Driver 57001 143 57001 1434 875701435 875714348 Piston Pin Assembly Camshaft Bearing Remover 57001
51. 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Turn the crankshaft pulley A clockwise so that the timing mark B on the pulley aligns with the reference point C on the timing gear case cover OCheck that the rocker arms at 1 cylinder are free If not turn the pulley one more turn to free the rocker arms e Using a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem cap C x If the valve clearance is incorrect adjust it Valve Clearance Standard 0 20 mm 0 0079 in OWhen positioning 1 piston TDC at the compression stroke Inlet valve clearance of 1 and 3 cylinders Exhaust valve clearance of 1 and 2 cylinders Front A Measuring Valve B OTurn the crankshaft pulley 360 clockwise Inlet valve clearance of 2 cylinder Exhaust valve clearance of 3 cylinder Front A Measuring Valve B Valve Clearance Adjustment e Loosen the valve adjusting screw locknut A e Turn the valve adjusting screw B until the correct clear ance is obtained e Holding the adjusting screw tighten the locknut Torque Valve Adjusting Screw Locknuts 11 1 1 97 in Ib EX IN EX IN EX IN oe 3 2 1 e 1807000 81 lt P EX IN EXIN EX IN des e 1807001 81 PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Spark Arrester Cleaning WARNING The muffler can become extremely hot during n
52. 5 Install the duct so that the long side faces frame 6 Position the outlet boot downward 7 KAF950G9 GA HA G Apply grease R Replacement Parts 3 4 FUEL SYSTEM Exploded View KAF950G9 GC HA 16020798885 FUEL SYSTEM 3 5 Exploded View Temm Nm kgfm fttb 1 2 swbuorHesdBot 17 3 Fuel Fiter Mounting Bos 20 20 18 4 Fuel injection Nozzles s 44 5 Fuel injection Pipe Clamp Bots 74 075 6 Fuel injection Pipe Mounting nus 25 28 18 Fuel injection Pump Bracket Bots 20 20 15 8 Fuel injection Pump GearNut_ 6 68 a 9 Fuel injection Pump Mounting Nuts 20 20 15 710 idie Adjusting Screw Locknut 69 970 Linkage Pipe Nuts 28 20 712 Maximum Speed Set Screw Locknut 69 00 eime 3 Air Vent Hose E Check Valve 15 Fuel Output Hose from Fuel Filter to Fuel Injection Pump 16 Fuel Output Hose from Fuel Tank to Fuel Filter 17 Fuel Return Hose from Fuel Injection Pump to Fuel Tank 18 KAF950G9 GA HA AD Apply adhesive G Apply grease R Replacement Parts 3 6 FUEL SYSTEM Exploded View KAF950GD 2 N 10207485 FUEL SYSTEM 3 7 Exploded View re remm ge Nm kgfm fttb 1 2 swbuorHesdBo
53. Circlip A Washer B Ramp C Spring D Movable Sheave E Spacer Fixed Sheave with Shaft 1 07004 82 Wear Shoe Mounting Screws A Wear Shoes B 1 07002 81 Driven Pulley Inspection x If the sheave surfaces A appear damaged replace the sheaves e Replace any sheave which has uneven wear on the belt contacting surface Straight Edge B x If the guide bushings A are damaged or worn replace the movable sheave Sheave Bushing Inside Diameter Standard 39 655 39 965 mm 1 561 1 573 in Service Limit 40 mm 1 57 in 6 26 CONVERTER SYSTEM Driven Pulley x If the splines A of the fixed sheave and ramp are dam aged or worn replace them x If the spring is damaged replace the spring Spring Free Length A Standard 137 5 mm 5 41 in x If the tabs on the spring are misaligned or the spring coils are distorted replace the spring OOne side end B of the spring must be maintained to 10 from other side end 1 07017 82 Converter Driven Pulley Shoe Inspection e Refer to the Converter Driven Pulley Shoe Inspection in the Periodic Maintenance chapter CONVERTER SYSTEM 6 27 Driven Pulley Driven Pulley Assembly e Install the wear shoes on the movable sheave B as shown in the figure OThe wear shoe shall be installed so that the mark C on the shoe faces outward e Apply a non permanent locking agent to the wear shoe mounting s
54. Defective fuel injection nozzle 10120048 FUEL SYSTEM 3 27 Fuel Injection Pump Troubleshooting Excessive Exhaust Smoke No good Check to see if injection timing is proper Adjust injection timing Good No good Check to see if fuel filter is contained water Drain water from fuel filter and tank Good INN i No good Check to see if fuel filter is restricted Replace fuel filter Good Check to see if fuel injection nozzle is STENT Jon Defective fuel injection nozzle functioning properly Good Malfunctioning injection pump Engine keeps racing No good Check to see if throttle cable moves smoothly Lubricate replace and or adjust and has specified free play throttle cable Good 1 Malfunctioning injection pump 2 Crankcase may be overfilled with oil 3 Excessive hydrocarbon vapors near the vehicle 10120058 3 28 FUEL SYSTEM Fuel Injection Pump Troubleshooting Excessive Fuel Consumption No good m retighten fittings to upper limit of torque Good No good Check to see if idling speed is too high Adjust idling speed Good No good Check to see if maximum engine speed under no load Check maximum speed set state is too high screw on injection pump Good No good Check to see if injection timing is proper Adjust injection timing Good TUNE No good Check to see if fuel injection nozzle is functioning TM Defective fuel injectio
55. EPS Warning Indicator Light LED Removal e Remove Control Panel see Control Panel Removal in the Frame chapter Nut A EPS Warning Indicator Light LED B 15 46 STEERING EPS Electric Power Steering System EPS Warning Indicator Light LED Inspection e Remove Front Cargo Compartment see Front Cargo Compart ment Removal in the Frame chapter Speedometer Cable Upper End A e Disconnect the EPS warning indicator light LED lead connectors R Lead B BK W Lead C e Using two auxiliary leads connect the 12 V battery A to the EPS warning indicator light LED lead connectors as follows EPS Warning Indicator Light LED Inspection Connections Battery Terminal R Lead Battery Terminal BK W Lead the EPS warning indicator light LED A does not light up replace it see EPS Warning Indicator Light LED Re moval x If EPS warning indicator light LED lights up check the following items Oil Pressure Switch Oil Pressure Warning Indicator Light x If the above items are normal check the wiring for conti nuity Refer to the next wiring diagram STEERING 15 47 EPS Electric Power Steering System EPS Warning Indicator Light LED Circuit 10908026882 EPS ECU EPS Warning Indicator Light LED EPS Fuse 7 5 A Oil Pressure Warning Indicator Light Main Switch Battery 12 V 52 Ah Main Fuse 30 A Fuse Box 2 Oil Pressure Switch
56. FINAL DRIVE 12 25 Bevel Gear Adjustment Procedure Adjust gear backlash Adjust tooth contact pattern Assemble the bevel gear assembly completely 1050178 1105014 81 12 26 FINAL DRIVE Bevel Gear Case Bevel Gear Case Backlash Related Parts 195015802 1 Driven Gear Shim s 7 Driven Bevel Gear 2 Drive Gear Shim s 8 Hi Low Gear Case 3 Driven Gear Shaft 9 Drive Gear Shaft 4 Bearing Housing 10 Ball Bearing 5 Bevel Gear Case 11 Gasket 6 Ball Bearing 12 Drive Bevel Gear 1 Driven Gear Shims 0 004 in 0 15 mm 6 006 05 mm 0 020 in 0 8 mm 0 031 in 92025 1862 1 0 mm 0 039 in primary 92025 1858 1 2 mm 0 047 in 92025 1863 FINAL DRIVE 12 27 Bevel Gear Case 2 Drive Gear Shims 015 mm 0 006 in 09 mm 0 035 in 1 0 mm 0 039 in primary 1 1 mm 0043 in 12 mm 0047 in 13 mm 0 051 in Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the driven bevel gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use this for checking the
57. Font Cargo Companen se 16 18 Front Cardo Hood ReMOV al PEDE 16 18 Front Cargo HOO 5 16 18 Front Cargo Hood Cable 16 19 Front Cargo Compartment Removal esses nenne eene esee 16 19 Front Cargo Compartment Installation pp 16 19 icio MNT TT EI 16 20 Cargo Bed Beloved ER EE 16 20 RAO OSC INS EIN 16 20 Front Genter and Rear Bass udo LUE pars 16 22 Front REMOVA 16 22 ront 16 22 16 22 Rear ratus 16 23 Center Bar REMOVA 16 23 Center Bar utu Qnia uad 16 24 Cargo Bed Lateh MSpectONnN 16 24 Cargo Bed Latch Position 16 25 US 16 26 Front Guard Removal 16 26 Front Guara
58. ODo not short the cables that are directly connected to the battery positive terminal to the chassis ground ODo not turn the main switch ON while any of the EPS electrical connectors are disconnected The EPS ECU memorizes service codes ODo not spray water on the electrical system parts EPS system parts connectors leads and wiring Olf a transceiver is installed on the vehicle make sure that operation of the EPS system is not influenced by electric wave radiated from the antenna Locate the antenna as far as possible away from the EPS ECU OWhenever the electrical connections of the EPS system are to be disconnected first turn the main switch OFF Conversely make sure that all the electrical connections of the EPS system are firmly reconnected before turning on the main switch OWhen reconnecting the connector connect these connec tors securely until they click A OThe EPS system parts should never be struck sharply as with a hummer or allowed to fall on a hard surface Such a shock to the parts can damage them OThe EPS system parts can not be disassembled Even if a fault is found do not try to disassemble and repair the EPS system parts replace it OWith the front wheel lifted from the ground do not move the front wheel quickly An abnormal voltage is generated and the EPS ECU may be damaged OUsing a fully charged battery If the power supply voltage of the EPS ECU becomes 10 V or less EPS system does not ope
59. Tapping Screw B and Collar e Remove Side Mounting Bolts A Left and Right Front Cargo Compartment B Front Cargo Compartment Installation e Installation is the reverse of removal note the following parts size screws A L 16 mm 0 63 in and Collars L 4 mm 0 16 in screws B L 22 mm 0 87 in and Collars L 6 mm 0 24 in Tapping Screw C L 16 mm 0 63 in and Collar L 4 mm 0 16 in 16 20 FRAME Cargo Bed Cargo Bed Removal e Remove the rear fender assembly see Rear Fender As sembly Removal e Open the clamps A and disconnect the tail brake light lead connectors B left and right e Remove Left and Right Bolts C Tail Brake Light Assemblies D e Open the steal clamp on the cargo bed and free the lead e Unlock the hooks A e Raise the rear seat and push it toward the front seat back to store e Remove Left and Right onap Pins A Cargo Bed Mounting Pins B e Remove the cargo bed Cargo Bed Installation e Installation is the reverse of removal note the following OApply lithium grease Grade No 2 to the cargo bed mounting pins OCheck that the following are in place on the cargo bed and frame Cargo Bed Rubber Dampers A Frame Rubber Dampers B Tail Gate Pivot Rubber Dampers Left and Right Cargo Bed e When the cargo bed is disassembled note the following when installing the plates and tail gate OBe sure the clearance A betwee
60. Throttle Cable Fix the differential shift cable 2WD AWD shift cable and speedometer cable with the clamp Be sure that there is clearance between the cables and the shaft drive Fix the transmission shift cable and hi low shift cable with the band Clamp Differential Shift Cable Keep 25 mm 0 98 in or more clearance between the rear shock absorber and differential shift cable Run the cable on the outside of right rear brake hose 2WD AWD Shift Cable Keep 25 mm 0 98 or more clearance between the rear shock absorber and 2WD AWD shift cable Run the cable on the outside of right rear brake hose Transmission Shift Cable Band Speedometer Cable Front Right Side View of Rear Area Set the white mark between center bracket and clamp 18 20 APPENDIX Cable Wire and Hose Routing Run the speed sensor lead through inside of the 2WD AWD shift cable and differen tial shift cable Band Tail Brake Light Lead 80 mm 3 15 Clamp Band Neutral Switch Lead Detail A Fill up lithium grease Grade 2 1808158 4 Band Neutral Switch Lead 80 mm 3 15 in the tube at both ends 490 500 mm 19 3 19 7 in Front View from Top Upper Right Detail B Detail C Cable Wire and Hose Routing Floor Cent
61. Wheel Cylinder Removal Installation 13 20 Wheel Cylinder ASSemlbly aet tache toe atus tne le 13 20 Wheel Cvylinder InSpeellOLizsmu acies oae pad teque no oe ud dete 13 21 Brake Sho Lining Wear c cR 13 21 Brake Shoe Spring Inspection eee nnn nnne nenne marem n e 13 21 Grease Seal rad Pergit tx E Dore vex 13 22 Parking Brake Lever and Cables pp 13 23 Parking Brake Lever Travel Adjustment pp 13 23 Parking Brake Cable Lubrication Inspection pp 13 23 13 2 BRAKES Exploded View Q s e Q 2 2 Q BRAKES 13 3 Exploded View of a sa os Bn 2 Brake Hose Barjo Bos 25 28 18 73 Brake Pipe Nipples 18 19 8 74 Front Axe Nuts e 200 i 75 Front Brake Panel Mounting Bos 44 48 32 i 6 Front Wheel Cynder Mounting Bots 103 14 Sin 77 Master Cylinder ReservoirCap 34 035 Bin 8 Piston Stopet _ 88 090 in e n2 ow m 110 Reservoir Campet 61 082 54mb Brake Master Cylinder E Brake Pedal 13 Left Front Brake Drum 14 Right Front Brake Drum 15 Bands for Breather Tube of Early Model for KAF950G9 16 Breather Tube Early Model for KAF950G9 1 480 mm 58 3 in Late Model for KAF950G9 and Later Model L 1 100 mm 43 3 in AG Ap
62. are positioned as shown in the figure 1 Idle Gear AA A Crankshaft Gear 2 Idle Gear C CC or C Fuel Injection Pump Drive Gear 3 Idle Gear BB B Camshaft Drive Gear e Install the oil pump drive gear A and bolt CRANKSHAFT CRANKCASE 9 11 Timing Gear Case e install the flywheel A to hold the crankshaft OUsing the flywheel holder B angled toward the rear of the engine hold the crankshaft Special Tool Flywheel Holder 57001 1438 e Install the thrust plate A e Tighten Torque Idle Gear Bolts B 25 N m 2 5 kgf m 18 ft Ib e Position the flywheel holder to the forward side of the en gine e Tighten Torque Fuel Injection Pump Drive Gear Nut C 64 N m 6 5 kgf m 47 ft Ib Camshaft Drive Gear Bolt D 43 N m 4 4 kgf m 32 ft lb Oil Pump Drive Gear Bolt E 20 Nm 2 0 kgf m 15 ft lb e Install New Timing Gear Case Cover Gasket Dowel Pins F e Confirm the small hole in the oil nozzle A faces the en gagement of the idle gear and camshaft drive gear e Tighten Torque Oil Nozzle 14 N m 1 4 kgf m 10 1 e Install Timing Gear Case Cover Bracket A e Tighten Torque Timing Gear Case Cover Bolts 7 8 N m 0 80 kgf m 69 in Ib 55 mm 2 17 in B 45 mm 1 77 in C 30 mm 1 18 in D 9 12 CRANKSHAFT CRANKCASE Timing Gear Case e Position the flywheel holder A back to the rear side of the engine as shown in the f
63. bevel gears e Turn the driven bevel gear for 3 or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear e Check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and a little closer to the toe of the tooth x If the tooth contact pattern is incorrect replace the shim s at the drive bevel gear and shim s at the driven bevel gear following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shims are replaced Repeat the shim change procedure as necessary NOTE Olf the backlash is out of the standard range after chang ing shims correct the backlash before checking the tooth contact pattern Drive Bevel Gear A Driven Bevel Gear B Bottom C Top D Heel E Toe F 12 28 FINAL DRIVE Bevel Gear Case Incorrect Tooth Contact Patterns Example 1 Increase the thickness of the drive bevel gear shim s by 0 05 mm 0 002 in and or increase the thick ness of the driven bevel gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Drive Bevel Gear A Driven Bevel Gear B Bottom C Top D Heel E Toe F Example 2 Decrease the thickness of the drive bevel gear shim s by 0 05 mm 0 002 in
64. converter case B while pushing down the leaf spring rear end Torque Converter Case Installation e Be sure to install the following on the drive shaft and trans mission case Collar A O ring B e Confirm the engine and transmission case position see Engine Installation in the Engine Removal Installation chapter CONVERTER SYSTEM 6 13 6 14 CONVERTER SYSTEM Torque Converter e Replace the nut B with a new one e Install Torque Converter Case A Nut and Washer C e Apply a non permanent locking agent to the following bolts and install them Converter Case Bolts lt 55 mm 2 17 in D Converter Case Bolts 28 mm 1 10 in E e Tighten Torque Converter Case Bolts 55 mm 27 2 8 kgf m 20 ft Ib Converter Case Bolts L 28 mm 20 N m 2 0 kgf m 15 1 e Tighten damper bracket nuts in order as shown in the figure Front A Outside B Torque Damper Bracket Nuts First 20 2 0 kgf m 15 ft lb Second 44 4 5 kgf m 32 ft Ib Final 59 N m 6 0 kgf m 44 ft Ib e Install the removed parts See appropriate chapters Torque Converter Case Disassembly e Remove Torque Converter Case A see Torque Converter Case Removal Oil Seal B Ball Bearing C Trims D if necessary Torque Converter Case Assembly e Apply transmission oil to the ball bearing e Press the ball bearing A until it is bottomed Special Tool Bearing Driver Set 57001 11
65. does not blink or lights up turn the main switch OFF and repeat from fourth procedure again OLastly turn the main switch OFF within 5 seconds after indicator light blinks two times end the service code erase mode x If the main switch is not turned OFF within 5 seconds the EPS ECU starts the EPS neutral position registration NOTE OThe EPS neutral position registration is same procedure as until eighth procedure OAfter finishing the service code erase mode enter the self diagnosis mode again to confirm that the service codes have been erased If all codes have been erased the EPS warning indicator light LED remains lit and service code is not indicated STEERING 15 35 15 36 STEERING EPS Electric Power Steering System Service Code Erasing Flow Chart EPS Warning Indicator Light LED State Turn the main switch OFF Connect an auxiliary lead to the terminals of the EPS self diagnosis system connector Lift the front wheel off the ground Turn the steering wheel fully to the left and keep it Start the engine while turning the steering wheel fully to the left Indicator light LED lights up for 4 seconds and goes off Turn the main switch OFF MG Free the hands from the steering wheel Indicator light LED lights up Turn the steering wheel fully to the left and keep it Indicator light LED goes off Free the hands from the steering wheel Indica
66. place e Tighten Torque Bevel Gear Case Bolts 22 N m 2 2 kgf m 16 ft Ib Bevel Gear Case Disassembly e Remove Speed Sensor see Speed Sensor Removal in the Elec trical System chapter Holder Nuts A Covers B Holder C 105018 81 x If the driven gear assembly is to be disassembled loosen the housing locknut A Special Tools Pinion Gear Holder B 57001 1281 Socket Wrench C 57001 1363 068019 P FINAL DRIVE 12 23 Bevel Gear Case e Remove Driven Gear Assembly A Driven Gear Shim s B e Remove Housing Locknut Bearing Housing A Special Tools Pinion Gear Holder B 57001 1281 Socket Wrench C 57001 1363 e Remove the driven gear shaft nut A Special Tool Pinion Gear Holder B 57001 1281 OPressing the spring seat C remove the driven gear shaft nut e Remove the bearing holder A Special Tool Hexagon Wrench Hex 40 B 57001 1324 e Remove the ball bearings Special Tools Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 Bevel Gear Case Assembly e Install the housing locknut so that the chamfered side B faces to the bearing e Apply a non permanent locking agent to the threads of the following parts Driven Gear Shaft Nut Bearing Holder Housing Locknut e Tighten Torque Driven Gear Shaft Nut 108 N m 11 0 kgf m 79 7 ft Ib Bearing Holder 118 N m 12 0 kgf m 87 0 ft lb Housing Locknut 118 12 0 kgf m 87 0 ft
67. replace it Front Axle Joint Boot Replacement Outboard Joint Boot Removal e Remove Front Axle see Front Axle Removal e ap the joint portion of the bands A with a suitable tool e Scrap the removed boot bands e Slide the joint boot B toward the inboard joint e ap the bearing housing A straight B with a plastic ham mer to separate it from the shaft NOTICE Do not tap on the cage Be careful not get hurt when the housing comes out If the splined portion of shaft cracked or damaged during disassembling of outboard joint do not reuse the shaft e Remove Circlip A Boot B Drive Shaft and Axles Outboard Joint Boot Installation e Clean the axle shaft by wiping off the used grease on it e Wind the tape on the splines of the axle shaft in order to protect the joint boot e Install New Small Band A New Boot B OApply the special grease slightly on the inside of the new boot small diameter and install the boot on the axle shaft NOTICE Only the special grease that is included with the boot kit can be applied to the boots e Install New Circlip C e Place the special grease tube nozzle in the bore of the housing and squeeze the tube A until the grease comes out from the joint bearing e ap the shaft end A straight with a plastic hammer until it is locked by the circlip e Squeeze all of the special grease into the bearing housing A and new boot B FINAL DRIVE 12 37
68. 12 Light Switch 13 Preheating Timer 14 Radiator Fan Breaker 15 Radiator Fan Relay 16 Starter Circuit Relay 17 Horn Button 18 KAF950GB 19 KAF950G9 GA HA 20 KAF950GD G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant 17 8 ELECTRICAL SYSTEM Exploded View AN SE 4 T SS 1902078BW5 C ELECTRICAL SYSTEM 17 9 Exploded View EE Mus T gm OR 1 SpeedSensorBot 88 090 Bint KAF950G9 GC HA Ground Lead Connection Horn Horn Switch Contact Steering Gear Assembly Hour Meter Fuel Gauge Hour Meter Speedometer Replacement Parts Apply transmission oil ODOMDNDORWND 17 10 ELECTRICAL SYSTEM Exploded View EUR Model 1002024BW5 ELECTRICAL SYSTEM 17 11 Exploded View 1 Reverse Light 2 Reverse Light Switch 17 12 ELECTRICAL SYSTEM Wiring Diagram KAF950G9 GA HA EPS ECU EPS Fuse 40A kN E DE ES x gt Pots e Bur R W Fuse EPS Motor EPS Torque EPS Speed EPS Warning lt Sens Self2diaghosis Sensor Indicator Light LEB System Connector Accessory Connector AA 12V 120W Power Butlet 1 BR gt BR BK Y Hour Meter Radiator Fan d R BL BK Y
69. 14 14 SUSPENSION Leaf Springs and Dampers Leaf Spring Installation e When installing the rubber bushings to the leaf spring lubricate them with a soap and water solution NOTICE Do not use engine oil or petroleum distillates to lu bricate the bushings because they will deteriorate the rubber e Install the rear wheel temporarily and ground it to load the suspension during the mounting nut tightening e Tighten Torque Leaf Spring Mounting Bolts Front 98 N m 10 0 72 3 ft lb Leaf Spring Mounting Nuts Rear 59 N m 6 0 44 ft lb Rear Shock Absorber Mounting Nuts 59 N m 6 0 44 ft lb e Apply liquid gasket to the threads of the leaf spring bracket Sealant Three Bond 1364D e Replace the damper bracket mounting nuts with new ones e Tighten the damper bracket mounting nuts in the order as shown in the figure Front A Outside B Torque Damper Bracket Mounting Nuts First 20 2 0 kgf m 15 ft lb Second 44 4 5 kgf m 32 ft Ib Final 59 N m 6 0 kgf m 44 ft Ib e Apply brake fluid to the brake pipe nipple threads e Tighten Torque Brake Pipe Nipples 18 N m 1 8 13 ft Ib e Bleed the brake line see Brake Line Air Bleeding in the Brakes chapter Leaf Spring Inspection e Visually inspect the leaf spring for breaks or distortion x If the leaf spring is damaged any way replace it e Check the rubber bushings in the mounts and the dampe
70. 144 STEERING 15 19 10078014 10078015 15 20 STEERING EPS Electric Power Steering System Parts Location EPS Warning Indicator Light LED A EPS Motor A B KAF950G9 GC HA C KAF950GD EPS Torque Sensor A EPS Unit B with EPS Motor and EPS Torque Sensor EPS ECU A EPS Electric Power Steering System Speed Sensor A EPS Self diagnosis System Connector A EPS Fuse Box 1 EPS Fuse 40 A B EPS Fuse Box 2 EPS Fuse 7 5 A C STEERING 15 21 15 22 STEERING EPS Electric Power Steering System EPS System Wiring Diagram KAF950G9 GA HA T 3 1 EPS ECU 8 EPS Fuse 7 5 A 2 EPS Fuse 40A 9 Oil Pressure Warning Indicator Light 3 EPS Motor 10 Main Switch 4 EPS Torque Sensor 11 Battery 12 V 52 Ah 5 EPS Self diagnosis System Connector 12 Main Fuse 30 A 6 Speed Sensor 13 Fuse Box 2 7 EPS Warning Indicator Light LED 14 Oil Pressure Switch OColor Codes BK Black P Pink BL Blue R Red BR Brown W White G Green Y Yellow STEERING 15 23 EPS Electric Power Steering System EPS System Wiring Diagram KAF950GB 1 1088038BW3 1 EPS ECU 9 EPS ECU Relay 2 EPS Fuse 40 A 10 Diodes 3 EPS Motor 11 Oil Pressure Warning Indicator Light 4 EPS Torque Sensor 12 Main Switch 5 EPS Self diagnosis System Connector 13 Battery 12 V 52 Ah 6 Speed Sensor 14 Main Fuse 30 A 7 EPS Warning Indicator Light LED 15 Fuse Box 2 8 EPS Fuse 7 5 A
71. 16 Oil Pressure Switch OColor Codes BK Black P Pink BL Blue R Red BR Brown W White G Green Y Yellow 15 24 STEERING EPS Electric Power Steering System Terminal Names e 9 11 12 113 15 20 21 22 23 10908001882 1 Unused 2 Unused 3 Unused 4 Ground for EPS ECU BK Y 5 Power Supply from Battery W 6 EPS Motor 1 BK T EPS Motor 2 R 8 External Communication Line G 9 EPS Warning Indicator Light LED BK W 10 Unused 11 Unused 12 Speed Sensor Signal P 13 Unused 14 Unused 15 EPS Torque Sensor Signal 1 Y BK 16 Power Supply from Main Switch BL R 17 Unused 18 Unused 19 Unused 20 EPS Self diagnosis System Terminal BL 21 Unused 22 Ground for EPS Torque Sensor BK BL 23 EPS Torque Sensor Signal 2 Y R EPS Electric Power Steering System EPS System Servicing Precautions There are number of important precautions that should be followed servicing the EPS system OThe EPS system operates while running the engine OThis EPS system is designed to be used with a 12 V bat tery as its power source Do not use any other battery except for a 12 V battery as a power source ODo not reverse the battery cable connections This will damage the EPS ECU OTo prevent damage to the EPS system parts do not dis connect the battery cables or any other electrical connec tions when the main switch ON or while the engine is run ning
72. 2 Radiator Fan Switch 3 Radiator Fan 4 Battery 5 Radiator Fan Breaker 17 54 ELECTRICAL SYSTEM Meter Gauge Speedometer Removal e Remove Front cargo compartment see Front Cargo Compart ment Removal in the Frame chapter Band A e Disconnect the speedometer illumination lead connector B e Remove Speedometer Cable A Meter Bracket Bolts B and washers e Remove the speedometer A backward B e Remove Speedometer screws A and washers B Speedometer bracket C and washers D Speedometer E Remove the rubber dampers as necessary e Remove the rubber dampers as necessary Speedometer Installation e Install the following parts as shown in the figure Rubber Dampers A Washers B Speedometer Bracket C Speedometer Screws D Speedometer E Install the two rubber dampers of speedometer bracket so that its thicker side faces meter side e Apply a non permanent locking agent to the threads of the speedometer screws 1019015881 ELECTRICAL SYSTEM 17 55 Meter Gauge Fuel Gauge Hour Meter Removal KAF950GD e Remove the front cargo compartment see Front Cargo Compartment Removal in the Frame chapter e Clear the clips A and remove the stopper B e Remove the fuel gauge hour meter C Fuel Gauge Hour Meter Installation KAF950GD e Installation is the reverse of removal ORun the harness cables and leads correctly see Cable Wire and Hose Routing section in the Appendix
73. 5 F 40 40 C 68 104 1 6 212 248 284 60 80 100 120 140 160 1180 200 1220 240 260 280 300 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents dd 2 3 Torg e and 2 5 SPO CIM COU ONS 2 11 2 13 Periodic Maintenance 2 14 x CIENT P 2 14 Throttle Pedal Play InSDectlOli iudi eee ea onte ner m Educ eus 2 14 Throttle Pedal Play AG Poe 2 14 Idle Sbeed 4 2 15 despbesu AdUStMEN a ea enon ne er eee eee nee 2 15 Fuel Hoses and Connections Inspection pp 2 15 ITI 2 15 Fuel Filter Element Replacement nennen nnn 2 17 iter Water DRAINING 2 17 SY SUS Mace as eset wn cara e 2 18 Radiator Cleaning ET Ned Um 2 18 Radiator Hose and Connection Inspection pp 2 18 Coolant CAN GC MERE m I TT 2 18 Cooling Fan
74. 79 in Wheelbase 2 165 mm 85 24 in Track Front 1 160 mm 45 6 in Rear 1 180 mm 46 46 in Ground Clearance 180 mm 7 09 in Seat Height Front 855 mm 33 66 in Rear 880 mm 34 64 in Curb Mass KAF950G9 GC HA 788 kg 1 738 Ib KAF950GD 795 kg 1 75316 Front KAF950G9 GC HA 349 kg 770 Ib KAF950GD 355 kg 783 Ib Rear KAF950G9 GC HA 439 kg 968 Ib Fuel Tank Capacity Cargo Bed L x W x H Long Bed KAF950G9 GC HA 1 280 x 1 212 x 287 mm 50 39 x 47 72 x 11 30 in KAF950GD 1 280 x 1 210 x 285 mm 50 39 x 47 64 x 11 22 in Short Bed KAF950G9 GC HA 770 x 1 212 x 287 mm 30 31 x 47 72 x 11 30 in KAF950GD 770 x 1 210 x 285 mm 30 31 x 47 64 x 11 22 in Seating Capacity Front 2 Rear 2 Performance Minimum Turning Radius 3 9 m 12 8 ft Engine Type 4 stroke OHV Diesel 3 cylinders Cooling System Liquid cooled Bore and Stroke 72 x 78 mm 2 83 x 3 07 in Displacement 953 cm 58 2 cu in Compression Ratio 24 8 Maximum Horsepower 17 7 kW 24 PS Q3 600 r min rpm CA US Maximum Torque 52 5 3 38 4 ft lb 2 800 r min rpm CA US Injection Pump Denso VE type Starting System Electric starter General Specifications tems 5069 GENERAL INFORMATION 1 9 Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Gr
75. A straight out of the EPS fuse box 2 B Fuse Installation x If a fuse fails during operation inspect the EPS system to determine the cause and then replace it with a new fuse of proper amperage OFor EPS fuse 40 A after installing the lead terminals tighten the terminal bolts securely Fuse Inspection e Remove the fuse see EPS Fuse 7 5 A Removal EPS Fuse 40 A Removal e Refer to the Fuse Inspection in the Electrical System chapter OFor EPS fuse 40 A there is window for inspection in the upper surface FRAME 16 1 Frame Table of Contents wie mA m HX pup 16 3 Seats dnd SEAL Bells bip piena 16 12 Front Seat SemoVvalinsaete actu duo oue bte ide LE 16 12 Front seatclnstallatioliaxe Doubt etc coto xu Pc tus 16 12 Rear Seat Removal cse tue eve arm LAM EE Ca E DUE 16 13 Rear Seat Installatlopis A LN DI DC 16 14 Searbel semowveli decedens 16 14 sistat bo hose iac 16 15 CO 16 16 Control Panebiermovel eedem mete ru LE E 16 16 Control Panel Installation 4 16 17 Glove a aaa 16 17
76. Batlnsbeelgi ee 2 21 Engine feodo EE 2 23 Valve clearance aL Cid cB ee M 2 23 Valve Clearance Adjustment god 2 24 Spaik Arrester Ga 2 25 Seni Nei Eo omm 2 25 Blige TU T TM 2 25 Drive Belt Detlecton Irnspecllolnass us c deett C ies RR eu eda tns ta 2 26 Drive Belt Deflection Adjustment pp 2 27 Converter Driven Pulley Shoe Inspection 2 27 Converter Air Cleaner Element Cleaning Inspection pp 2 28 LUDHCOCSIOD SVSEIOETI dee n based dei d 2 29 Engine Oil and or Oil Filter Change pp 2 29 OILFINS REMOVA TT RE 2 30 SS 2 30 NSS 2 30 ranmsmlssiao 2 30 ES 2 31 Wheels Nuts Tightness nspection pp 2 31 WIKE VVCal 8 2 31 uwin BB 2 31 Front Final Gear Case OI Charge e en ced ues cuiu acus 2 31 EB AIK OS d 2 32 Brake Fluid Level Inspection pp 2 32 Brake GANANG t 2 33 Brake Pedal Play Inspection 2 34 Brake Master Cylinder Cup and Dust Seal
77. C Spring D Shift Shaft and Arm E 10 30 TRANSMISSION Differential Gears and Shift Mechanism Differential Shift Mechanism Installation e Insert the shift shaft A in the gear case e Replace the O ring C with a new one e nstall the new O ring and apply molybdenum disulfide grease to it e Push the shift shaft A as shown in the figure e Install Washer B Shift Shaft Stop Bolt C e Tighten Torque Shift Shaft Stop Bolts 7 8 0 80 kgf m 69 e Wipe off any protruding grease e Install the spring A e Turn the shift shaft B clockwise until stop and hold it e Install the shift shaft lever C on the shift shaft so that the lever is position like the figure e Tighten the shift shaft lever mounting nut D e Hook the spring end E as shown in the figure Differential Shift Mechanism Inspection e Visually inspect the following parts Splines on Drive Shaft A Splines on Shifter B Dogs C on Shifter Shifter Groove D e Visually inspect the following parts Shift Arm Pin A Dogs B on Differential Gear Housing If they are damaged or worn excessively replace them 1J098007BS1 1J08008BS1 TRANSMISSION 10 31 Differential Gears and Shift Mechanism e Replace parts worn beyond the service limit Shift Arm Pin Diameter A Standard 8 4 8 6 mm 0 331 0 339 in Service Limit 8 3 mm 0 327 in Shifter Groove Width B Standard 9 0 9 1
78. Clearance e Measure connecting rod big end side clearance Olnsert a thickness gauge between the connecting rod big end A and either crank web B to determine clearance If the clearance exceeds the service limit replace the con necting rod with a new one and then check clearance again If the clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Side Clearance Standard 0 15 0 28 mm 0 0059 0 0110 in Service Limit 0 3 mm 0 0118 in CRANKSHAFT CRANKCASE 9 21 Crankshaft and Connecting Rods Connecting Rod Inspection e Measure the inside diameter A of the connecting rod small end x If the connecting rod small end bore has worn past the service limit replace the connecting rod Connecting Rod Small End Service Limit Inside Diameter 18 03 mm 0 7098 in 11070028851 e Measure the inside diameter A of the connecting rod big end OWith bearings removed install the connecting rod cap e Tighten Torque Connecting Rod Cap Nuts 36 N m 3 7 kgf m 27 ft Ib x If the connecting rod big end out of round exceeds the service limit replace the connecting rod 107003 81 Connecting Rod Big End Service Limit Out of Round 0 02 mm 0 0008 in e Check for a bent or twisted connecting rod NOTE OThe thrust faces must be free of any burrs or nicks or the connecting rod will not lay flat on a surface plate OPut the c
79. Connecting Plate Nuts 1 2 N m 0 12 kgf m 11 in Ib Glow Plug Inspection e Using the x 1 O range of the hand tester measure the resistance between the terminal A and the housing B of the glow plug Special Tool Hand Tester 57001 1394 x If the tester does not read as specified replace the glow plug Glow Plug Resistance About 0 1 5 0 O NOTE OBe careful not to apply the battery voltage to the glow plug directly OBe careful not to scratch the heater section C ELECTRICAL SYSTEM 17 47 17 48 ELECTRICAL SYSTEM Preheating System Preheating Timer Inspection e Remove the front seat lower cover left see Starter Relay Inspection e Check that the main switch is turned OFF and connect the hand tester A to the preheating timer B as follows Special Tool Hand Tester 57001 1394 Hand Tester Range DC 25 V Hand Tester Lead Black Lead Terminal Hand Tester Lead Ground e When the main switch is turned ON the reading should show less than 1 8 V during 5 seconds x If the preheating timer does not work replace the timer Glow Plug Relay Inspection e Remove Front Seat Lower Cover Left see Starter Relay Inspec tion Mounting Bolt A and Nut Glow Plug Relay B Glow Plug Relay Lead Connectors C e Connect the hand tester A and 12 V battery B to the glow plug relay C as shown in the figure Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay
80. EPS ECU A So the direction distinction circuit itself can not be inspected e Turn the main switch OFF e Disconnect the EPS ECU and EPS motor connectors e Check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector A EPS Motor Connector B R Lead Terminal C BK Lead Terminal D x If the wiring is good check the power supply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation 1008016851 Boosting Transformer Circuit Inspection Service Code 37 OThe boosting transformer circuit is built in the EPS ECU A So the boosting transformer circuit itself can not be inspected STEERING 15 43 EPS Electric Power Steering System e Turn the main switch OFF e Disconnect the EPS ECU and EPS motor connectors e Check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector A lt EPS Motor Connector B R Lead Terminal C BK Lead Terminal D x If the wiring is good check the power supply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation 1008016
81. Front B x If there is any signs of deterioration cracks or damage replace the steering gear assembly together with these boots 1004000851 1005001851 PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Frame Seat Belt Inspection e Check the belts A for damage or tear x If necessary replace the belt with a new one e Check the tightness torque of the seat belt mounting bolts B Torque Seat Belt Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Seat Buckle Mounting Bolts C 34 3 5 25 ft lb ae e Check the operation of the buckle OSet the plate B in the buckle and confirm the plate does not come off when pulling it OSet the plate in the buckle and confirm the plate comes off when the buckle button C is pushed x If operation is not correct visually inspect the plate x If the plate is damaged replace the plate assembly with a new one x If the plate is not damaged replace the buckle assembly Electrical System Electrolyte Level Inspection Conventional Type Battery A WARNING Electrolyte contains sulfuric acid which is harmful to skin eyes and clothing Wear eye protection and rubber gloves If spillage occurs on body or clothing rinse at once with water for at least 15 minutes e Remove the filler caps A on the battery OLift the side of the cap B opposite the terminals and then lift the
82. 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 Force Use common sense during disassembly and assembly excessive force can cause expensive or hard 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 performance Remove old gaskets and clean the sealing surfaces thor oughly so that no gasket material or other material remains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking 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
83. Ib 2 3 2 4 mm 0 091 0 094 in 2 1 mm 0 083 in 2 7 2 8 mm 0 106 0 110 in 2 4 mm 0 094 in 1 5 3 0 0 15 0 31 kgf 0 34 0 67 Ib 0 3 0 6 N m 0 03 0 06 kgf m 2 6 5 2 in Ib 0 14 0 69 mm 0 0055 0 0271 in at ditch portion of the pinion gear slotted nut 0 07 0 15 mm 0 0028 0 0059 in at middle of gear dog side on drive gear shaft FINAL DRIVE 12 7 Special Tools Bearing Puller Socket Wrench 57001 135 57001 1283 875701355 875712838 Outside Circlip Pliers Pinion Gear Holder m1 0 57001 144 57001 1285 875701445 875712858 Oil Seal amp Bearing Remover Hexagon Wrench Hex 40 57001 1058 57001 1324 ST571058ST 875713248 Bearing Driver Set Socket Wrench 57001 1129 57001 1363 875711295 875713635 Pinion Gear Holder Transmission Gear Holder 57001 1281 57001 1676 875712818 6 T5716768T 12 8 FINAL DRIVE Front Final Gear Case Front Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove Front Final Gear Case Skid Plate Nuts and Bolts A Front Final Gear Case Skid Plate B e Remove the filler cap A NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bot tom of the filler opening A x If it is i
84. If the spring is damaged replace the cylinder e Check the brake shoe clearance adjuster for damage front brake only x If it shows any damage replace the cylinder Dust Seal A Piston B Cup C Shoe Clearance Adjuster Front D Spring Rear E Brake Shoe Lining Wear e Refer to the Brake Wear Inspection in the Periodic Main tenance chapter Brake Shoe Spring Inspection e Visually inspect the brake shoe springs A for breaks or distortion x If the springs are damaged any way replace them Front Brake Panel Install the upper shoe spring in the original position shown noting the hook direction e Install the lower spring inside the plate of the shoe Rear Brake Panel Install the upper shoe springs in the original position shown noting the relative position of the coil to the parking brake lever linkage e Install the lower spring inside the plate of the shoe Er p p ff ae n if 2 H me a i BRAKES 13 21 13 22 BRAKES Brake Panel Assemblies Grease Seal Replacement e Remove Brake Panel Assy see Brake Panel Assy Removal Grease Seal A NOTICE Be careful not to damage the brake panel when re moving the grease seal e Install the grease seal A to specified position as shown in the figure Top Surface of Grease Seal B Center Bottom of Brake Panel C 11 2 12 0 mm 0 44 0 47 in D NOTE the following special tool Grease Seal Driver Set is use
85. OLoosen once and tighten again when the slot goes past the nearest hole HJ07007BS1 e Bend the cotter pin A over the nut B e Check the toe in of the front wheels see Toe in Adjust ment in the Wheels Tires chapter e Be sure to register the neutral position of the EPS see EPS Neutral Position Registration J04109BS1 Knuckle Bearing Removal e Remove Steering Knuckle see Steering Knuckle Removal Grease Seal A e Drive the bearing A out using a suitable bearing driver from the bearing driver set Special Tool Bearing Driver Set 57001 1129 Knuckle Bearing Installation e Press in the bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Replace the grease seal with a new one Steering Knuckles Knuckle Joint Removal e Remove oteering Knuckle see Steering Knuckle Removal Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove the knuckle joint A using a press Special Tool Knuckle Joint Remover B 57001 1619 OFirst press the knuckle joint until the remover end C touches the knuckle OSecond move the remover A so that its center align with the center of the knuckle joint OPress the knuckle joint and remove it Knuckle Joint Installation e Press the knuckle joint A until it is bottomed Special Tool Knuckle Joint Driver B 57001 1640 e Replace the circlip with a new one Special Tool Outside Circlip Pliers 57001
86. Play Adjustment 3 10 Full Throttle Pedal Position Adjustment pp 3 10 Throttle ut ite otn Ex nd ee INE RI 3 11 Throttle Cable eb esee ae 3 11 Throttle Cable dnspecllObls 3 11 US HNN mm HE 3 12 Fuel Injection NozzZle IetrioVal n ita tene edes 3 12 Fuel Injection Nozzle Installation o ceo pb en ede e aedes deeds 3 12 Fuel Injection Nozzle Inspection pp 3 12 mutus OTE 3 15 5 e Uv Cesta edt ce e v tt a 3 15 Idle Speed AGIUSITTIQUL soa Ue gro ctus 3 15 Maximum Engine Speed Inspection pp 3 15 Maximum Engine Speed Adjustment pp 3 15 PUGH INJECUON PDE CIIOV Al a 3 15 Fuel Injection Pipe Installation pp 3 16 Eel dnjecHion PUMO REMOVA csse tut te Mead gue 3 17 Fuel injection Pump Inst llallOr sten enn eco 3 17 Fuel Injection Pump Timing Inspection pp 3 18 Fuel Injection Pump Timing Adjustment pp 3 19 Fuel Injection Pump Inspection and Repair pp 3 21 Fuel Injection Pump Troubleshooting pp 3 22
87. Radiator Fan Motor Inspection e Disconnect the fan motor lead connector A from the har ness e Using two auxiliary leads supply battery power to the fan motor x If the fan does not rotate at this time the fan motor is defective and must be replaced Radiator Fan Motor Leads Red Battery Black Battery Radiator Fan Breaker Inspection e Tilt up the front seat e Remove Battery Cables see Battery Removal Radiator Fan Breaker A e Inspect the breaker for operation e Connect 12 V Battery A 0 3 O Resistance B Radiator Fan Breaker C owitch D x If the circuit in the breaker will not open within 60 seconds replace the breaker 1014003851 17 52 ELECTRICAL SYSTEM Radiator Fan Radiator Fan Relay Inspection e Remove Front Seat Lower Cover Left see Starter Relay Inspec tion Radiator Fan Relay Lead Connector A Radiator Fan Relay B e Connect the hand tester A and 12 V battery B to the radiator fan relay C as shown in the figure Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected 0 Q When battery is disconnected Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 GP11046BS2 C ELECTRICAL SYSTEM 17 53 Radiator Fan Radiator Fan Circuit 1914008812 C 1 Radiator Fan Relay
88. Reflector KAF950GC CA Models 12 KAF950G9 GC HA AD Apply adhesive G Apply grease L Apply a non permanent locking agent R Replacement Parts 16 8 FRAME Exploded View FRAME 16 9 Exploded View 771 2 Seat Belt Mounting Bots a 38 25 3 KAF950G9 GA HA AD Apply adhesive G Apply grease R Replacement Parts 16 10 FRAME Exploded View 4 A FRAME 16 11 Exploded View e Femer 3 Fix the bolt to inside from outside 4 18 mm 0 71 in 5 Dampers AD Apply adhesive G Apply grease L Apply a non permanent locking agent R Replacement Parts 16 12 FRAME Seats and Seat Belts Front Seat Removal e ilt up the seat A e Remove Seat Bracket Nuts B Seat Brackets C Seat e Remove Caps Seat Back Mounting Nuts A Seat Back B KAF950G9 GA HA D KAF950GB Front Seat Installation e Installation is the reverse of removal note the following OReplace the seat bracket nuts and seat back mounting nuts with new ones OApply lithium grease Grade No 2 to the inner sur face of the seat bracket OBe careful not to overtighten the seat bracket nuts After tightening the nuts the seat must be moved up and down smoothly Olnstall the front seat back so that its thicker side B faces downward OApply adhesive to the caps P03016BS 1 C FRAME 1
89. Rivets D Rear Fender Assembly Removal e Remove Screws A and Collars Rear Fender B FRAME 16 27 16 28 FRAME Fenders e Remove Tapping Screws A Bolt B Collar and Nut Rear Fender Stay C e Remove Bolts A Collars and Nuts Rear Fender Inner Cover B FRAME 16 29 Covers Front Cover Removal e Tilt up the front cargo hood e Remove Front Fenders see Front Fender Removal Front Guard see Front Guard Removal ocrews A and Collars Left and Right Bolts B and Washers Left and Right e Disconnect the head light connecters A Left and Right e Remove the front cover B with head lights assembly Front Cover Installation e Installation is the reverse of removal note the following OCheck that the clip nuts A left and right are in place as shown in the figure OAttach the rubber damper A of the bracket to the dent B of the front cover Front Fender Inner Cover Removal e Remove Front Fender see Front Fender Removal Tapping Screw A and Collar Quick Rivets B Front Fender Inner Cover C Middle 16 30 FRAME Covers e Remove Tapping Screws A and Collars Quick Rivets B Front Fender Inner Cover C Front e Remove Middle Cover see Middle Cover Removal Tapping Screws A and Collars Screws B Nut C and Collar Quick Rivets D Front Fender Inner Cover E Rear Front Fender Inner Cover Installation e Installation is the reverse of removal no
90. Side Clearance Adjustment 6 19 Dive Pulley ASSeribly 6 21 Bushing 6 22 TT x 6 22 BU H 6 24 BENE 6 24 Driven Pulley Disassembly pp 6 24 Driven DE I E IE 6 25 Converter Driven Pulley Shoe Inspection pp 6 26 Driven pPullev ASSGITDIV mete test Lore 6 27 Diven Pulley Installatlor ss senso tuo 6 28 6 2 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 6 3 Exploded View Nm km fib _ 1 Air CleanerHousing Mounting Bots 16 16 142 2 Air Cleaner Housing Mounting Bots 20 20 15 Converter Gover Bos 44 046 74 orive Pueys 98 6 5 DePuleyCovrBots 13 msme 6 FanCovrBots 88 Bib 7 merCowrBos 44 045 8 RamWegnNus 69 070 R 25 28 28 10 KAF950G9 and Early Models R Replacement Parts 6 4 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 6 5 Exploded View Driven s 98 69 t 74 merCoerNu 88 99 Bib R G Apply grease L Apply a non permanent locking agent R Replacement Parts TO Apply transmission oi
91. Special Tools Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 e Using the hexagon wrench A remove the bearing holder B and remove the drive bevel gear shaft bearing Special Tool Hexagon Wrench Hex 32 57001 1194 e Apply molybdenum disulfide oil solution to the threads of the drive bevel gear shaft bearing holder e Install the bearing holder so that the projections B face to outside e Tighten Torque Bearing Holder 118 12 0 kgf m 87 0 ft Ib e Using a press and the bearing driver set install the new bearings and or new oil seals Special Tool Bearing Driver Set 57001 1129 Ball Bearing Inspection e Turn each bearing back and forth A while checking for roughness or binding x If roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Needle Bearing Inspection e Check the needle bearing OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Visually inspect the oil seal Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged TRANSMISSION 10
92. Steering Gear Assembly Steering Gear Assembly Removal e Remove Front Wheels see Wheel Removal in the Wheels Tires chapter Radiator see Radiator Removal in the Cooling System chapter Cotter Pins Both Sides Tie Rod End Nuts A Both Sides Tie Rod Ends B from Steering Knuckles Both Sides NOTICE Do not loosen the end locknuts C or toe in of the front wheels will be changed the tie rod end A from the steering knuckle us ing a suitable joint remover B e Remove Left Radiator Side Cover see Radiator Side Cover Re moval in the Frame chapter Water Hoses A Horn Ground Lead Terminal B e Remove the steering gear assembly bracket bolts C and brackets D e Remove the rubber dumpers A 15 14 STEERING Steering Gear Assembly e Remove the mounting bolts A of the water pipe res 57 i UL ys 1 Malla a n i ly EL E Ba 2 e Remove the universal joint clamp bolt If the clamp bolt becomes hard to turn search the posi tion that it can be easily turned while turning the steering wheel slowly e Pull out the rubber boot B upward temporary e Move the steering gear assembly and pull off the shaft A from the lower universal joint B OLower the steering gear assembly and then pull it for ward e Remove the rubber boot C e Remove the steering gear assembly A from the v
93. Stem Cap OMark and record the valve stem cap locations so they can be installed in their original positions e Using the valve spring compressor A remove the split keepers Special Tool Valve Spring Compressor 57001 1433 e Remove Retainer A Valve Spring B e Remove Valve A Spring Seat B Oil Seal C Valve Installation e Replace the oil seal A with a new one e Apply engine oil to the new oil seal e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install Cil Seal Valve B Spring Seat C Valve Spring D Retainer E Split Keepers F 05003 81 Valves Valve Guide Removal e Remove Valve see Valve Removal opring Seat Oil Seal e Hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 05 5 57001 1021 Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Press the valve guide A in from the top of the head us ing the valve guide driver B until the driver bottoms on cylinder head Special Tool Valve Guide Driver 57001 1432 Valve Seat Inspection e Remove the valve see Valve Removal e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the corr
94. Torque Pinion Gear Bearing Housing Nuts 25 N m 2 5 kgf m 18 ft Ib e Adjust Front Final Gear Backlash see Backlash Adjustment Front Final Gear Tooth Contact see Tooth Contact Ad justment Differential Unit and Ring Gear Disassembly e Remove the differential unit and ring gear see Front Final Gear Case Disassembly NOTICE Do not interchange the right and left side parts in the differential unit e Remove the following parts to disassemble the differential unit Differential Case Cap Bolts A Differential Case Cap B OThe clutch plates springs spring shims and side gears come Out Differential Unit and Ring Gear Assembly e Inspect the clutch plates see LSD Clutch Plate Inspec tion and the other differential unit parts Replace any damaged parts e Measure and record the thickness of the original clutch spring shim e Apply specified gear oil to the differential unit parts e Note direction and position of the friction plate and the clutch spring Clutch Spring Shim A Clutch Spring B Outside Friction Plate C Steel Plate D Inside Friction Plate E e Be sure to assemble the differential unit and inspect the clutch torque see LSD Clutch Torque Inspection e Tighten Torque Differential Case Cap Bolts 32 3 3 kgf m 24 ft Ib FINAL DRIVE 12 11 IL04054B32 12 12 FINAL DRIVE Front Final Gear Case x If the ring gear is removed install it as follows Olnsert the pin A to
95. When measured with a spring scale the preload is designated by force N kgf Ib and when measured with a torque wrench it is des ignated by torque N m kgfm in Ib FINAL DRIVE 12 15 12 16 FINAL DRIVE Front Final Gear Case Front Final Gear Case Backlash Related Parts Ring Gear Shims for Backlash Adjustment 92025 1850 92025 1851 92025 1856 92025 1857 92025 1849 7 Collar for Preload Adjustment Thickness aa 92027 1401 92027 1402 92027 1403 92027 1404 92027 1405 92027 1406 92027 1407 92027 1408 92027 1409 92027 1410 92027 1411 R4 3 4 9 6 21 8 3 9 0 1 2 I 9 10 11 12 13 14 15 16 Pw 3 p 8 Shims for Preload Adjustment TINTE 10 92025 1072 92025 1073 92025 1074 92025 1075 92025 1076 92025 1077 72 74 76 78 80 IE CIL II Bi 19 8 5 2 8 9 Pinion Gear Shims for Tooth Contact Adjustment 92025 1919 92025 1920 92025 1921 92025 1922 92025 1923 92027 1924 Ring Gear Cover Front Final Ring Gear Ring Gear Shims for Pin Ball Collar for Preload Adjustment Gear Case Backlash Adjustment Bearing affects prrload only Shims for Preload Adjustment affects preload only Pinion Gear Shims for Tooth Contact Adjustment Differental Case Cap Pinion Gear Tapered Roller Bearing Pinion Gear Be
96. While pushing the shoe hold down spring B turn the pin C 90 and remove the shoes D individually NOTE OWrap the brake shoes with a clean cloth to protect the linings from grease or dirt OTo prevent the rear pin E from dropping into the rear axle bracket tape the pin onto the brake panel e Remove the collar F on the rear brake panel Front C e Remove the following for rear brake panel removal Cotter Pin A Joint Pin B Parking Brake Lever Linkage C e Remove Brake Panel Mounting Bolts A Rear Brake Panel B 13 18 BRAKES Brake Panel Assemblies Brake Panel Assembly Front Brake Panel e Apply lithium grease NLGI Grade No 2 to the following portion Brake Panel Seating Surface Between Axle and Panel e Install the brake panel and wheel cylinder e Apply a non permanent locking agent to the threads of the brake panel mounting bolts e Tighten Torque Front Brake Panel Mounting Bolts 44 4 5 kgf m 32 ft lb Front Wheel Cylinder Mounting Bolts 10 3 N m 1 1 91 in Ib e Apply grease to the following portions Contact Points A of Brake Panel and Brake Shoes Wheel Cylinder Piston Ends B Brake Shoe Anchor Ends C e Apply brake fluid to the threads of the brake pipe nipple and tighten it Torque Brake Pipe Nipples 18 N m 1 8 13 ft Ib OThe wheel cylinder has a brake shoe clearance adjuster e Turn A either end of the cylinder fully while holding t
97. and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accu mulate and can cause internal shorting If the temperature of the electrolyte rises above 45 113 F during charging reduce the charging rate to lower the temperature and increase charg ing time proportionately e Remove the battery see Battery Removal NOTE attempt to charge a frozen battery OAllow it to warm up to room temperature before charg ing ONever leave a battery on a trickle charger longer than 48 hours Serious damage to the battery will occur Conventional Type Battery e Charge the battery with a current of 1 to 1 5 amps until the specific gravity rises to 1 250 and temperature reaches 15 5 60 F e Refer to the Battery Charging Time Table for the charging o cO e o gt D Battery Charging Time Table Charging Hours 1 5A Constant Current Battery e Check the electrolyte level after charging x If the electrolyte level is low add water only after initial activation WARNING Electrolyte contains sulfuric acid which is harmful to skin eyes and clothing Wear eye protection and rubber gloves If spillage occurs on body or clothing rinse at once with water for at least 15 minutes e Turn the charger off or plug it then disconnect it from the battery x If the battery condition indicates that it i
98. and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum e Inspect the parking brake lever see Parking Brake Lever Inspection Parking Brake Lever Inspection e Check parking brake lever travel A by feeling clicks OPull the parking brake lever B upward slowly all the way Count the number of notches clicks during lever travel OThe vehicle should not roll while parked Parking Brake Lever Travel Standard 8 12 notches clicks at 200 20 kgf 44 Ib e Release the parking brake and return the lever to its rest position PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures x If the lever travel is not correct adjust it e Pull up the rubber boot A e oosen the locknut B and turn the adjusting nut C to obtain the correct amount of lever travel e Tighten the locknut e Check the parking brake for good braking power and when released no brake drag A WARNING Insufficient free play can cause brake heating and drag resulting in skidding and loss of control which could cause an accident resulting in serious injury or death Be sure the brake free play is adjusted to the specification NOTE Olf the parking brake lever travel cannot be adjusted with the adjusting nut at the lever remove the cover A and use the adjusters B behind the parking brake lever an
99. and check the oil level The oil level should be between the upper F and lower L level marks A x If the oil level is too high remove the excess oil Remove the dipstick pipe and using a syringe or some other suit able device through the opening or removing the engine oil drain plug drain the excess 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter x If the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine Oil Filler Cap A NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely NOTICE To avoid the engine damage do not fill the engine oil above the full level Engine Oil and or Oil Filter Change e Refer to the Engine Oil and or Oil Filter Change in the Periodic Maintenance chapter Oil Filter Removal e Refer to the Oil Filter Removal in the Periodic Mainte nance chapter Filter Installation e Refer to the Oil Filter Installation in the Periodic Mainte nance chapter ENGINE LUBRICATION SYSTEM 7 9 Oil Pan and Oil Strainer Oil Pan and Oil Strainer Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Flywheel and End Plate see End Plate Removal in the Crankshaft Crankcase c
100. and or decrease the thick ness of the driven bevel gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Drive Bevel Gear A Driven Bevel Gear B Bottom C Top D Heel E Toe F Bevel Gear Case Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin A the bearing by hand to check its condition x If the bearing B is noisy does not spin smoothly or has any rough spots replace it Oil Seal Inspection e the oil seals Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged Damper Inspection e Visually inspect the driven bevel gear A cam follower B spring C and shaft D Replace part that appears damaged FINAL DRIVE 12 29 6J08040831 12 30 FINAL DRIVE Propeller Shafts Propeller Shaft Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Tapping Screws A Plate B e Remove the tapping scr
101. and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 31 F Total Amount 4 4 L 4 7 US qt Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi Thermostat Valve Opening Temperature 81 84 C 178 183 F Valve Full Opening Temperature 95 203 F COOLING SYSTEM 4 5 Flow Chart This engine has a pressurized forced circulation cooling system The water pump circulates coolant through the cylinder block cylinder head and radiator The ther mostat maintains optimum engine temperature The thermostat is equipped with a by pass valve which permits coolant to re circulate through the cylinder block and cylinder head As the engine warms the by pass valve closes as the thermostat opens permitting complete cir culation through the radiator Always maintain 50 solution of phosphate free antifreeze at all times for adequate heat dissipa tion lubrication and protection from freezing Thermostat Thermostat Closed e 5525502 XXX 1 9 ZIC 5555 LA SESS 99 4 02004 XS 10093002882 Water Pump Thermostat Air Bleed Bolt Reserve Tank Radiator Radiator Cap Drain Bolts Front 4 6 COOLING SYSTEM Coolant Coolant Level Inspection NOTE OCheck the level when the engine is cold room
102. cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 0004020182 Bolts Nuts and Fasteners Tightness Inspection e Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OCheck the engine fastener tightness when the engine is cold at room temperature x If there are loose fasteners first loosen by 1 2 turn then retorque them to the specified torque following the speci fied tightening sequence Refer to the appropriate chap ter for torque specifications If torque specifications are not in the appropriate chapter see the basic torque table Bolt Nut and Fasteners to be checked Engine Engine Mounting Bolts Exhaust Pipe and Muffler Joint Bolts Exhaust Pipe Holder Nuts Fuel Tank Bolt and Nut Muffler Mounting Bolts Throttle Pedal Pivot Cotter Pin Transmission Final Drive 2WD AWD Shift Lever Pivot Snap Pin 2WD AWD Shift Shaft Lever Mounting Nut Axle Nuts and Cotter Pins Differential Shift Cable Upper End Snap Pin Differential Shift Lever Pivot Snap Pin Differential Shift Shaft Lever Mounting Nut Hi Low Shift Cable Upper End Snap Pin Hi Low Shift Lever Pivot Snap Pin Hi Low Shift Shaft Lever Mounting Nut Propeller Shaft Bearing Housing Nuts Shift Shaft Lever Clamp Bolts Transmission Shift Cable Upper End Snap Pin 2 48 PERIODIC MAINTENANCE Periodic Maintenance Pr
103. chapter Fuel Gauge LED Inspection KAF950GD e Remove the fuel gauge hour meter see Fuel Gauge Hour Meter Removal 1 Battery 2 Battery 4 Fuel Level Gauge 1919083851 e Using the auxiliary leads connect the 12 V battery to the fuel gauge hour meter connector as follows Battery Positive Terminal to Terminal 2 Battery Negative Terminal to Terminal 1 e Connect the variable rheostat A to the terminal 4 1019084851 e Check that the number of segments A matches the re sistance value of the variable rheostat OThe number of fuel gauge segments increases or de creases one by one every 10 seconds Variable Rheostat Displav Seaments Resistance Q di ds 1 blink x If the fuel gauge display function does not work replace the fuel gauge hour meter 1919085851 17 56 ELECTRICAL SYSTEM Meter Gauge Fuel Level Gauge Inspection KAF950GD e Remove Fuel Level Gauge see Fuel Level Gauge Removal in the Fuel System chapter e Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not move smoothly replace the fuel level gauge Float in Full Position A Float in Empty Position B Using a tester measure the resistance across the termi nals in the fuel level gauge lead connector Special Tool Needle Adapter Set 57001 1457 the tester readings are not as specified or do
104. color change or other damage x If there is any doubt as to the condition of a bearing re place it Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin A the bearing by hand to check its condition x If the bearing B is noisy does not spin smoothly or has any rough spots replace it 8 08040881 Oil Seal Inspection e Visually inspect the oil seal Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged 12 22 FINAL DRIVE Bevel Gear Case Bevel Gear Case Removal e Drain the transmission oil see Transmission Oil Change in the Periodic Maintenance chapter e Remove Cargo Bed see Cargo Bed Removal in the Frame chap ter Propeller Shaft see Propeller Shaft Removal Right Rear Wheel see Wheel Removal in the Wheels Tires chapter Speed Sensor Lead Connector A Bevel Gear Case Bolts B Bevel Gear Case C Bevel Gear Case Installation e Check and adjust the bevel gear backlash and tooth con tact when any of the backlash related parts are replaced see Bevel Gear Adjustment e Replace the bevel gear case gasket A with a new one e Check to see that the bevel gear case dowel pin B is in
105. e Install Speedometer Gear A Washer B New O ring C Bushing D Oil Seal E Thick Holder F Thin Holder G Bolt H e Adjust Transmission Oil see Transmission Oil Change in the Periodic Maintenance chapter Transmission Shift Cable see Shift Lever Position Ad justment Differential Shift Cable see Differential Shift Cable Ad justment Hi Low Shift Cable see Shift Lever Position Adjustment 2WD 4WD Shift Cable see 2WD 4WD Shift Cable Ad justment J05009BS1 TRANSMISSION 10 13 Transmission Case Transmission Case Splitting e Remove Transmission Case see Transmission Case Removal Bevel Gear Case see Bevel Gear Case Removal in the Final Drive chapter Hi Low Gear Case see Hi Low Gear and Shift Mecha nism Removal Cable Bracket A Bolts B Left Transmission Case C Transmission Case Assembly e Check to see that the transmission case dowel pins A are in place If any one of them has been removed re place it with a new one e Apply liquid gasket to the transmission case mating sur face Sealant Liquid Gasket TB1105B 92104 002 e Apply grease to the oil seal lips e Tighten Torque Transmission Case Bolts 8 8 0 90 kgf m 78 10 14 TRANSMISSION Transmission and Shift Mechanism Transmission and Hi Low Shift Cables Installation e Remove one side of the spring A from the shift shaft lever assembly e Put the shift lever A in the L LOW po
106. e Replace the thermostat housing gasket with a new one e Install the locating screw e Tighten Torque Thermostat Housing Cap Bolts 7 8 N m 0 80 69 in Ib e Adjust the coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature x If the valve is open replace the thermostat with a new one e o check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one 6009010151 Thermostat Valve Opening Temperature Standard 81 84 C 178 183 F Thermostat Valve Full Opening Temperature Standard 95 C 203 F 4 14 COOLING SYSTEM Hoses and Pipes Hose and Pipe Installation e Install the hoses and pipes being careful to follow bend 277 ys ing direction or diameter Avoid sharp bending kinking flattening or twisting e Install the clamps A as near as possible to the hose end to clear the raised rib or the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting an
107. e When installing run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and run the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Fit the fuel hose A onto the fitting fully and install the plate clamp B beyond the raised rib C 1 2 mm 0 039 0 079 in D OThe hose end must reach the filler E or be as near as possible to the step F e Bleed the air from the fuel filter see Fuel Filter Installation in the Fuel System chapter Fuel Filter Element Replacement e Remove Fuel Filter see Fuel Filter Removal in the Fuel System chapter Drain Cap A O ring B Filter Cartridge C OUse a suitable filter wrench e Install a new filter cartridge by hand until the gasket con tacts the housing Then tighten it 1 3 turn more e Install Drain Cap New O ring Fuel Filter see Fuel Filter Installation in the Fuel System chapter Fuel Filter Water Draining e Tilt up the cargo bed e Place a suitable container under the filter drain hose A e Loosen the air vent plug B e Loosen the drain cap C approximately 1 turn and drain water from the filter until only fuel flows from the filter e Tighten the drain cap securely e Bleed the air from the fuel filter see Fuel Filter Element Replaceme
108. gear tooth OHold the crankshaft OMove the idle gear back and forth noting indicator reading Timing Gear Backlash Service Limit 0 2 mm 0 008 in If the backlash exceeds the service limit check the idle gear bearing and shaft for wear Idle Gear Inside Diameter A Service Limit 34 17 mm 1 3453 in Idle Gear Shaft Outside Diameter B Service Limit 33 91 mm 1 3350 in x If the idle gear bearing and shaft are within the service limit replace the idle gear and recheck the backlash x If the backlash exceeds the service limit with a new idle gear crankshaft gear is worn x If the crankshaft gear is worn replace crankshaft e Check the timing gear backlash between the camshaft drive gear A and idle gear B OSet the tip of the dial gauge C on the camshaft drive gear tooth OHold the idle gear OMove the camshaft drive gear back and forth noting indi cator reading Timing Gear Backlash Service Limit 0 2 mm 0 008 in xIf the backlash exceeds the service limit replace the camshaft drive gear e Check the timing gear backlash between the fuel injection pump drive gear A and idle gear B OSet the tip of the dial gauge C on the fuel injection pump drive gear tooth OHold the idle gear the fuel injection pump drive gear back and forth noting indicator reading Timing Gear Backlash Service Limit 0 2 mm 0 008 in x If the backlash exceeds the service limit replace th
109. internal expansion Electrical Equipment Battery 12 V 52 Ah Headlight Type Semi sealed beam Bulb 12 35 W x 2 Brake Tail Light 12V 21 5 W x 2 Reverse Light EUR 12 V 10 W Alternator Type Three phase AC Rated Output 40 A 12 V Load Capacity Maximum Vehicle Load 740 kg 1 632 Ib Including Occupants and Cargo Maximum Cargo Bed Load Long Bed 499 kg 1 100 Ib Short Bed 318 kg 701 Ib Specifications are subject to change without notice and may not apply to every country GENERAL INFORMATION 1 11 Unit Conversion Table Prefixes for Units Units of Length 2 2 2 1 000 000 1 000 mm x 0 03937 in C 0 01 n 0 004 Units of Torque 0 000001 N m 0 1020 kgf m N m x 0 7376 ftlb N m 8 851 Units of Mass kgf m x 9 807 N m kg x 2 205 Ib x 7 233 g x 0 03527 OZ kgf m x 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgficm x 9807 L x 2113 pint US kgf cm x 14 22 psi L x 1816 pint IMP cmHg x 1 333 kPa mL x 0 03381 0 mL x 0 02816 0 IMP Units of Speed mL 0 06102 km h x 06214 Units of Force Units of Power ME ES kW x 1 360 PS kW x 1344 HP of ae 6S PS x 0 7355 eee PS x 0 9863 HP Units of Temperature
110. is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected 0 Q When battery is disconnected Q Relay Coil Terminals 85 and 86 Relay Switch Terminals 30 and 87 Glow Plug Relay Installation e Connect the leads to the glow plug relay terminals as fol lows Black Lead Tag No 85 to Terminal No 85 A Brown Lead Tag 86 to Terminal No 86 B Black White Lead Tag Terminal No 87 C No 87 Black White Lead Tag to Terminal No 30 D No 30 Preheating System Preheating System Circuit CD gt D AOR ON START I 9 L Bk w BK W 5 9 9 BR 6 6 W Neutral Switch Starter Circuit Relay Glow Plug Relay Glow Plug Light Main Switch Glow Plugs Battery Main Fuse 30 A Preheating Timer Fuse 5 A Fuse Box 2 Starter Relay Fuse 30 A Fuse Box 1 Preheating Timer ELECTRICAL SYSTEM 17 49 1017002BW3 17 50 ELECTRICAL SYSTEM Fuel Cut Solenoid Fuel Cut Solenoid The fuel cut solenoid A is in the fuel injection pump When the main switch is turned to the START position the fuel solenoid is energized and the solenoid valve B lifts against the spring C and opens the fill port D to the pressure chamber When the switch is returned to the ON position after the engine has started the current fl
111. mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oll 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following pm Cutter angle B Outer diameter of cutter GE15011831 Valves Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth NOTICE Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced e Measure the outside diam
112. occurs on body or clothing rinse at once with water for at least 15 minutes e Place the carton A on a flat surface as shown in the figure pull the tab back to edge of the carton e Pull out the hose B and cut off end of the hose e Fill each cell A until the electrolyte level rises to bottom B of the split ring C of the vent well NOTICE Do not fill into the split D Do not overfill e After filling cells wait five to ten minutes x If necessary to bring electrolyte to proper level add the additional electrolyte A WARNING Neutralize any residue with baking soda Rinse empty package with large quantities of water Destroy empty package to prevent accidents e Place the strips of filler caps A loosely over the filler ports e Charge the battery at 15 amps until specific gravity of electrolyte rises to 1 250 and a temperature of 15 5 C 60 F Both conditions must be met 1008006851 1908007851 1008008851 ELECTRICAL SYSTEM 17 29 Battery x If violent gassing or spewing occurs reduce the charge rate NOTICE Never allow a battery to get HOT to the touch If the battery is excessively hot to the touch discontinue charging immediately Allow the battery to cool down before monitoring gravities or continuing charge e After charging if the electrolyte level has fallen refill the battery with the electrolyte to upper level e Fit the filler caps A firmly 19080
113. off any excess grease e Install Collar A Rear Brake only Brake Drum BRAKES 13 13 IM08007BS1 13 14 BRAKES Brake Drums e Mount the brake drum holder A securely on the drum studs with the wheel nuts Special Tool Brake Drum Holder 57001 1325 e Using the brake drum pusher B and tighten it until the pusher stops Special Tool Brake Drum Pusher M18 x 1 5 57001 1261 e And then remove the pusher install the washer and axle nut e Tighten Torque Front Axle Nuts 196 N m 20 0 kgf m 145 ft lb Rear Axle Nuts 304 Nm 31 0 224 ft lb e Insert a new cotter pin NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole HJ07007BS1 e Bend the cotter pin A over the nut B A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin HJ07008BS1 Brake Drum Wear e Refer to the Brake Wear Inspection in the Periodic Main tenance chapter Brake Panel Assemblies Brake Panel Assy Removal Front Brake Panel e Remove Front Brake Drum see Brake Drum Removal Brake Hose Retainer Breather Hose A Brake Pipe Nipple B Front C Immediately wipe
114. oil pickup in the oil pan and pumps the oil through the oil filter The filtered oil flows through oil galleries in the crankcase and is distributed to the main bearings connecting rod bearings camshaft bearings and rocker arm shaft A pressure relief valve limits the maximum oil pressure in the system ROCKER ARM SHAFT CAMSHAFT OILNOZZLE p 4 L 4 Pd Ll ih d E p OIL PUMP EN nd NI OIL FILTER OIL STRAINER ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection NOTE Olf the vehicle has just been used wait several minutes for all the oil to drain down the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches every part can cause engine seizure e Park the vehicle on level ground and tilt up the seat e Pull out the dipstick A out of the dipstick tube wipe it dry and insert it into the tube securely e Pull out the dipstick
115. olPumpDreGesBo 3 20 20 15 T OlStamerMoumingBotandNus 78 080 emb 78 ReetVavegot 39 40 29 EO Apply engine oil G Apply grease LG Apply liquid gasket R Replacement Parts SS Apply silicone sealant 7 4 ENGINE LUBRICATION SYSTEM Specifications Limit Engine Oil and Oil Filter Engine Oil Grade API CF or CF 4 Viscosity SAE 10W 40 Capacity 3 0 L 3 2 US qt When filter is not removed 3 3 L 3 5 US qt When filter is removed Level Between F and L marks on dipstick Oil Pump Oil Pump Side Clearance 0 030 0 096 mm 0 0012 0 0038 in 0 15 mm 0 0059 in Oil Pump Housing Depth 12 63 12 67 mm 0 4972 0 4988 12 72 mm 0 5008 in Relief Valve Relief Valve Spring Free Length 34 5 36 5 mm 1 358 1 437 in Oil Pressure Measurement Oil Pressure 196 490 kPa 2 0 5 0 kgf cm 28 71 psi at 3 000 r min rpm Oil temperature 55 65 C 131 149 F ENGINE LUBRICATION SYSTEM 7 5 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Liquid Gasket TB1211 57001 164 56019 120 875701645 ST5601208T 6 Oil Pressure Gauge Adapter PT 1 8 57001 1033 875710335 7 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart This engine has a full pressure lubrication system with an oil filter The gear driven oil pump draws oil from a screened
116. part is cold at room temperature e Check wiring and connections from the EPS ECU con nector to the suspected faulty EPS system part using the hand tester Special Tool Hand Tester 57001 1394 STEERING 15 27 0080028 5 15 28 STEERING EPS Electric Power Steering System e Visually inspect the wiring for signs of burning or fraying x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the hand tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the main harness B if necessary e Narrow down suspicious parts and close in on the faulty EPS system part by repeating the continuity tests If no abnormality is found in the wiring or connectors the EPS system parts are the next likely suspects Check each part one by one If an abnormality is found replace the affected EPS sys tem part x If all the parts and wirings are good be sure to inspect the power supply voltage of the EPS ECU x If the power supply voltage is good replace the EPS ECU A
117. position e Tooth contact location is influenced by pinion gear posi tion more than by ring gear position 1104021 81 Front Final Bevel Gear Adjustment Procedure Preload the pinion gear bearing Adjust gear backlash Adjust tooth contact pattern Assemble the final gear case completely L04018B 5 Front Final Gear Case Bearing Preload Adjustment e Check and adjust the bearing preload in the following cases OWhen any of the parts listed below are replaced with new ones Pinion Gear Collar Shim Tapered Roller Bearings Pinion Gear Bearing Housing A Oil Seal Collar OWhen the pinion gear slotted nut B is loosened even if the nut is not removed e Install the pinion gear bearing housing and tighten the pinion gear slotted nut to the specified torque see Pinion Gear Unit Assembly e Do not install the oil seal and O rings and do not lock the washer until the correct bearing preload is obtained NOTICE To start with choose a shim or collar so that the bearings are just SNUG with NO play but also with NO preload An over preload on the bearings could damage the bearings e Apply specified gear oil to the bearings and turn the gears more than 5 turns to allow the bearings to seat e Measure the bearing preload Bearing preload is the force or torque which is needed to start the gear shaft turning NOTE OPreload can be measured either with a spring scale or a beam type torque wrench
118. replace it x If the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing sur faces with fine emery cloth if necessary Wheel Rim Replacement e Remove the wheel see Wheel Removal e Disassemble the tire from the rim e Remove the valve stem and discard it NOTICE Replace the air valve whenever the tire is replaced Do not reuse the air valve Plastic Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F WHEELS TIRES 11 7 05000 81 05001 81 6J05010831 11 8 WHEELS TIRES Wheels Rims e Install a new air valve in the new rim ORemowve the valve cap lubricate the stem with a soap and water solution and pull A the stem through the rim from the inside out until it snaps into place NOTICE Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber IK05002B 5 e Mount the tire on the new rim e Install the wheel see Wheel Installation WHEELS TIRES 11 9 Tires Tire Removal e Remove Wheel see Wheel Removal Valve Core Let out the air Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges NOTICE Do not lubricate the tire beads and rim flanges with IK06000B 5 engine oil or petroleum distillates becaus
119. resulting in loss of cooling effi ciency Radiator and Radiator Fan Radiator Installation e Install Dampers A Washers B Collars C Washers D the washers D so that the round side E faces to the collar C e Tighten Torque Radiator Mounting Bolts F 8 8 0 90 kgf m 78 in Ib e Connect Radiator Fan Switch Lead Connectors Radiator Fan Lead Connector e Install Radiator Hoses G Reserve Tank Hose H Clamps I e Run the hoses according to the Cable Wire and Hose Routing section in the Appendix chapter Radiator Fan Removal e Remove Radiator Radiator Fan Mounting Bolts A Radiator Fan Assembly B e Remove Shroud Mounting Bolts A Shroud B Radiator Fan Installation e Install the shroud A so that the recess B of the shroud fit on the stopper C of the radiator e Tighten Torque Shroud Mounting Bolts 6 0 0 61 kgf m 53 in Ib e Install Radiator Fan Assembly Radiator Fan Mounting Bolts e Tighten Torque Radiator Fan Mounting Bolts 6 0 0 61 kgf m 53 in Ib COOLING SYSTEM 4 11 4 12 COOLING SYSTEM Radiator and Radiator Fan Radiator Inspection e Check the radiator core If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparable de formed fins rep
120. side of the cap nearest the terminals 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures e he electrolyte level should be between the upper and lower levels OUpper level is bottom A of the split ring B OLower level is top of the plates C x If the level of electrolyte in any cell is below the lower level add only distilled water to the upper level of the cell NOTICE Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery Do not fill into the split D Do not overfill Electrolyte Specific Gravity Inspection Conventional Type Battery WARNING Electrolyte contains sulfuric acid which is harmful to skin eyes and clothing Wear eye protection and rubber gloves If spillage occurs on body or clothing rinse at once with water for at least 15 minutes e Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer ORead the level A of the electrolyte on the floating scale B Specific Gravity Standard 1 265 at 20 C 68 F x If the specific gravity is below 1 20 charge 70 the bat tery needs to be charged NOTE OThe specific gravity of the electrolyte varies with changes in temperature so the specific gravity reading must be corrected for the temperature of the electrolyte OCelsius Add 0 007 points to reading for each 10 50 F above 20 C 68 F or subtract 0 007 points for e
121. the hole of the ring gear B and dif ferential case C OApply a non permanent locking agent to the threads of the ring gear bolts e Tighten Torque Ring Gear Bolts 82 N m 8 4 kgf m 61 ft Ib LSD Clutch Torque Inspection e After assembling the differential unit and ring gear check the LSD clutch torque e Insert both front axles A in the differential unit B e Hold the left front axles ring gear side with a vise e Install the hub nut on the other axle e Measure the clutch torque using a torque wrench C OTurn the wrench at 180 degree 5 seconds of rotation speed LSD Clutch Torque Standard 7 8 13 Nm 0 8 1 3 kgf m 69 115 in Ib x If the clutch torque is out of the specified range disas semble the differential unit see Differential Unit and Ring Gear Disassembly and replace either of the clutch spring shim e Also check the clutch plates and replace them as neces sary see LSD Clutch Plate Inspection e o increase clutch torque increase the thickness of the shim OChange the thickness a little at a time e Recheck the clutch torque and readjust as necessary 1 AP AP 0 079 in 92180 0275 2 0 mm Front Final Gear Case LSD Clutch Plate Inspection e Visually inspect the friction plates and steel plates to see if they show any signs of seizure overheating or uneven wear x If any plates show signs of damage or if the friction plates have w
122. the plating is damaged Replace the pipe if it is rusted cracked especially check the fittings or if the plating is badly scratched see Brake Hose and Pipe Replacement 1814000 81 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement e o remove the brake pipe A unscrew the nipple B e o remove the hoses C remove the banjo bolts D and or pull out the retainers OThe front cargo compartment inside is shown e Immediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Use a new copper washer for each side of the hose fittings at the master cylinder e Apply brake fluid to the threads of the nipple B of the brake pipe A e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Nipples 18 N m 1 8 13 ft Ib e Check that the brake line has proper fluid pressure and no fluid leakage OThe left front brake drum is shown OThe left front knuckle is shown Brake Pipe A Nipple B Brake Hose C Retainer D OThe rear middle of the vehicle is shown with the cargo bed tilted up Brake Hose and Pipes A Nipples B PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures OThe middle left of the vehicle is shown with the cargo bed tilted up Brake Pipe A Nipple B Brake Hose C Retainer D To
123. the service codes except the service code 31 OWhen there are plural service codes in the memory of the EPS ECU the service codes are displayed from the lowest number code in the ascending order The display is repeated until the main switch is turned OFF or the auxiliary lead is disconnected from the terminals of the EPS self diagnosis system connector OFor example if two problems occurred in the order of 32 12 the service codes are displayed from the lowest number code in the order listed 12 32 12532 repeated Indication starts Servise Codel2 Servise Code32 Servise Godel2 Light LED 10th digit Unit digit 1 3s 30 35 1 35 1 35 1 35 0 35 0 35 ON Ill 2 6s FD II 0 55 0 4s Main Switch ON 1008009871 Service Code Erasing OThe service code memorized in the EPS ECU can not be erased even if the main switch is turned OFF or battery cables are disconnected ORefer to the Service Code Erasing Procedure for the ser vice code erasure STEERING 15 33 EPS Electric Power Steering System Service Code Table EPS Warning Indicator Light LED Failure Parts Power supply voltage from main switch is abnormal Power supply voltage from battery is abnormal EPS neutral position is unregistration Current sensor is trouble FET Field Effect Transistor for EPS motor is trouble Internal relay is trouble EPS ECU CPU Central Processing Unit i
124. the spi der x If the spring is damaged replace the spring Spring Free Length A Standard 77 mm 3 03 in 808011881 Spider Shoe Side Clearance Adjustment e Remove Drive Pulley see Drive Pulley Removal Drive Pulley Cover and Spring see Drive Pulley Disas sembly e Set the drive pulley A without the spring onto the pulley holders Special Tools Drive amp Driven Pulley Holder 57001 1412 Drive amp Driven Pulley Holder 57001 1473 e Install the following parts temporarily Dowel Pins Drive Pulley Cover B Two Bolts C at Dowel Pins 6 20 CONVERTER SYSTEM Drive Pulley e Turn the spider counterclockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at four posts using a thickness gauge D Shoe Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in the clearance is not within the specified range adjust it according to following chart Present Shoes Clearance Measurement 7 2 mm 49048 1087 0 283 in l 7 3 mm up to 0 05 mm 0 0020 in 49048 1088 0 287 7 4 mm 49048 1089 0 291 0 05 0 20 over 0 0020 to 0 0079 in 49048 1090 7 5 mm E standard clearance 0 295 in 7 6 mm 49048 1091 0 299 in mm 49048 1092 0 303 in 7 8 over 0 20 mm 0 0079 in 49048 1093 0 307 7 9 mm 49048 1094 0 311 in 8 0
125. to the Drive Belt Inspection in the Periodic Mainte nance chapter Drive Belt Deflection Inspection e Refer to the Drive Belt Deflection Inspection in the Peri odic Maintenance chapter Drive Belt Deflection Adjustment e Refer to the Drive Belt Deflection Adjustment in the Peri odic Maintenance chapter CONVERTER SYSTEM 6 15 1 05002 81 6 16 CONVERTER SYSTEM Drive Pulley Drive Pulley Removal e Remove Torque Converter Outer Cover see Torque Converter Outer Cover Removal Fan Cover Bolts A Fan Cover B e Install the drive pulley holder A and tighten it with the three Allen bolts B as shown in the figure Special Tool Drive Pulley Holder 57001 1548 e Remove the drive pulley bolt C and washers e Using the drive pulley holder A and drive pulley puller bolt B remove the drive pulley C from the crankshaft Special Tools Drive Pulley Puller Bolt 57001 1429 Drive Pulley Holder 57001 1548 Drive Pulley Disassembly e Hold the drive pulley holder A and drive amp driven pulley holder B in a vise Special Tools Drive amp Driven Pulley Holder 57001 1412 Drive amp Driven Pulley Holder 57001 1473 e Set the pulley onto the pulley holder e Remove Drive Pulley Cover Bolts A Drive Pulley Cover B CONVERTER SYSTEM 6 17 Drive Pulley e Remove the spring A e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pull
126. to the threads or crankpin when installing the connecting rod e Apply engine oil to the following parts Cylinder Bores Pistons and Piston Rings Bearing Inserts and Crankpins e Rotate the crankshaft so that the crankpin is at bottom of the stroke CRANKSHAFT CRANKCASE 9 19 Crankshaft and Connecting Rods e Insert the piston and connecting rod with the arrow A on the piston facing right side timing gears side OUsing the piston ring compressor grip B and the belt C lightly tap the top of the piston with a plastic mallet to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 550 567 57001 1096 e Apply engine oil to the threads of the connecting rod bolt e Install the connecting rod caps with ID mark A facing right side timing gears side e Tighten Torque Connecting Rod Cap Nuts 36 N m 3 7 kgf m 27 ft Ib OAfter tightening the cap nuts make sure the crankshaft rotates freely Crankshaft Removal e Remove Camshaft see Camshaft Removal Timing Gear Case see Timing Gear Case Removal Connecting Rods see Connecting Rod Removal Oil Seal Retainer Bolts A Oil Seal Retainer B and Gasket e Remove Crankshaft Main Bearing Cap Bolts A Crankshaft Main Bearing Caps B Crankshaft C Thrust Washers 3 Main Bearing e Remove the upper main bearing inserts from saddles and place with the respective bearing
127. up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove the brake panel mounting bolts A and then re move the brake panel assy B Rear Brake Panel e Remove Rear Brake Drum A see Brake Drum Removal Brake Hose Retainer Breather Hose B Cotter Pin and Joint Pin C Brake Pipe Nipple D Unscrew Immediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove the brake panel mounting bolts A and collar B and then remove the brake panel assy C BRAKES 13 15 1408000851 13 16 BRAKES Brake Panel Assemblies Brake Panel Assy Installation e Apply lithium grease NLGI Grade No 2 to the following portion Brake Panel Seating Surface Between Axle and Panel e Install the brake panel assy e Apply a non permanent locking agent to the threads of the brake panel mounting bolts Torque Front Rear Brake Panel Mounting Bolts 44 N m 4 5 32 e Apply brake fluid to the threads of the brake pipe nipple and tighten it Torque Brake Pipe Nipples 18 N m 1 8 13 ft Ib e Install the brake hose retainer e Bleed the brake line after brake drum installation see Brake Line Air Bleeding e Be sure to check the brake system for good braking power no bra
128. 026B 5 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 crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from right 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 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GME 5 08020238 5 8 02082 81 GENERAL INFORMATION 1 7 Model Identification KAF950G9 Left Side View KAF950G9 Right Side View 1 8 GENERAL INFORMATION General Specifications O KAF950G9 GD HA Dimensions Overall Length KAF950G9 GC HA 3 305 130 12 in KAF950GD 3 265 mm 128 54 in KAF950GD 440 kg 970 Ib KAF950G9 GC HA 24 2 L 6 4 US gal KAF950GD 24 L 6 3 US gal Overall Width KAF950G9 GC HA 1 486 58 50 in KAF950GD 1 485 mm 58 46 in Overall Height 1 925 mm 75
129. 09851 Charging Condition Inspection Sealed Battery Battery charging condition can be checked by measuring battery terminal voltage e Remove the battery see Battery Removal NOTICE Be sure to disconnect the negative cable first e Measure the battery terminal voltage 908010851 0 NOTE OMeasure with a digital voltmeter A which can be read to one decimal place voltage rminal Voltage lt x If the reading is below the specified refreshing charge is required Battery Terminal Voltage 25 50 75 100 Standard 12 6 V or more Battery Charge Refreshing Charg Te is required Note Good 1908011851 17 30 ELECTRICAL SYSTEM Battery Ordinary Charging DANGER Batteries produce an explosive gas mixture of hy drogen and oxygen that can cause serious injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This proce dure prevents sparks at the battery terminals which could ignite any battery gases NOTICE Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates
130. 1394 ST5713948T 15 6 STEERING Steering Wheel and Main Shaft Assembly Steering Wheel Position Adjustment e oosen the steering shaft mounting nuts A e Adjust the steering wheel position e Tighten the main shaft bracket mounting nuts securely Steering Wheel Free Play Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Wheel Centering e Test ride the vehicle x If the steering wheel is not straight when the vehicle is traveling in a straight line do the following e Check the tie rod length and adjust it if necessary e Remove the wheel cap and horn switch KAF950G9 GC HA see Steering Wheel and Steering Shaft Re moval e Remove the wheel cover KAF950GD see Steering Wheel and Steering Shaft Removal e oosen the self lock nut A e Push the vehicle in a straight line with no one aboard and stop it without turning the steering wheel e Remount the steering wheel so that it is straight ahead e Install Spring Washer B KAF950G9 GC HA Washer C KAF950GD D KAF950G9 GC HA E KAF950GD e Tighten Torque Self lock Nut 52 N m 5 3 kgf m 38 1 e Install Horn Switch and Wheel Cap KAF950G9 GC HA see oteering Wheel and Steering Shaft Installation Wheel Cover KAF950GD see Steering Wheel and oteering Shaft Installation e Be sure to register the EPS neutral position see EPS Neutral Position Registration STEERING 15 7 Steeri
131. 29 e Apply grease to the oil seal lip e Press the oil seal B in the case so that the oil seal surface is flush C with the case end When installing the trim add the glue to the place be tween bolt hole and bolt hole r IF04011BS1 1 406000851 1704012851 1704013851 Drive Belt Drive Belt Removal e Remove Drive Pulley see Drive Pulley Removal Torque Converter Inner Cover see Torque Converter In ner Cover Removal NOTE OBefore removing the drive belt observe the direction of the belt s printed information A such as manufac turer s name and arrow marks is facing so that it may be reinstalled on the pulleys to rotate in the same direc tion as originally installed e Remove the drive belt Drive Belt Installation NOTE OBe sure the printed information faces the same direc tion so the belt rotates in the same direction as origi nally installed When installing a new belt install it so the printed information A can be read from beside the vehicle e Installation is basically the reverse of removal e Loop the belt over the driven pulley e Install Torque Converter Inner Cover see Torque Converter In ner Cover Installation Drive Pulley see Drive Pulley Installation e Put the transmission in neutral and rotate the driven pul ley to allow the belt to return to the top A of the sheaves before measuring belt deflection Drive Belt Inspection e Refer
132. 3 12 BRAKES Brake Hoses and Pipes Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Inspection in the Peri odic Maintenance chapter Brake Hose and Pipe Replacement e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Drums Brake Drum Removal e Remove Wheel see Wheel Removal in the Wheels Tires chapter Cotter Pin A Axle Nut B OLoosen the axle nut while applying the brake and release the brake OYou can also loosen the axle nut using the brake drum holder special tool Special Tool Brake Drum Holder 57001 1325 e Be sure to release the parking brake when removing the rear brake drum e he brake drums are press fitted on the axles Use the brake drum remover set and rotor puller special tools to remove the drums OMount the brake drum remover on the drum studs with the remover nuts and washers parts in the remover set Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 A 57001 1216 Brake Drum Remover B 57001 1260 Brake Drum Remover Nuts C 57001 1326 Washers D 57001 1260 ODo not remove the drum bolts If a drum bolt is damaged replace the drum Brake Drum Installation e Apply lithium grease Grade No 2 to the brake drum grease seal lips A and inside B of the drum as shown in the figure Grease Seal C Brake Drum D ODo not allow grease to come in contact with the sliding area of the brake shoes and brake drum OWipe
133. 33 111008851 6J08002BS31 10 34 TRANSMISSION Transmission Sectional Figure PY T TRANSMISSION 10 35 Transmission Sectional Figure eeu WHEELS TIRES 11 1 Wheels Tires Table of Contents tb delere O VIEW 11 2 Emm 11 4 EARL 11 5 11 5 T 11 7 Wheel Al esed A a MTM LSU Latera e 11 7 VV ASST AA STANATION ois suni ten 11 7 rS 11 7 Wheel Rim 11 7 Mice P 11 9 TS SIO me T Em 11 9 SUN ALO IY 11 9 mU em 11 10 11 2 WHEELS TIRES Exploded View IK02004BW5 WHEELS TIRES 11 3 Exploded View re a hm Nm fb 11 4 WHEELS TIRES Specifications tem Standard Wheel Alignment Caster Camber Toe in Wheels Rims Rim Size Front and Rear Tires Standard Tire Front and Rear Tire Air Pressure when Cold Front Rear Maximum Tire Air Pressure to seat beads when cold Tire Tread Depth 7 5 non adjustable 0 8
134. 4 x If the hand tester does not show the specified values re place the switch Radiator Fan Switch Resistance Rising Temperature From OFF to ON at 86 90 C 187 194 F Falling Temperature From ON to OFF at 81 85 C 178 185 F ON Less than 0 5 Q OFF More than 1 GP18020232 Switches and Sensors Coolant Temperature Switch Inspection e Remove the coolant temperature switch see Coolant Temperature Switch Removal in the Cooling System chapter e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant so that the sensitive portions C are located in almost in the same depth NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the connector and the body at the temperatures shown in the table Special Tool Hand Tester 57001 1394 x If the hand tester does not show the specified values re place the switch Coolant Temperature Switch Resistance Rising Temperature From OFF to at 112 118 C 234 244 F Falling Temperature From ON to OFF within 10 C 50 F of temperature ON Less than 0 5 OFF More than 1 MO
135. 4000 82 CRANKSHAFT CRANKCASE 9 1 Crankshaft Crankcase Table of Contents tb delere 219 EN 9 2 SDE CIMC ANON S NT TRE mmm 9 4 318 SN 9 6 ore ge C T Tt EEUU 9 8 Timing Gear Case REMOVA accidit didt o e m OQ ea ttt tuu ede doors 9 8 s e um 9 9 Timing Gear Case Cover Oil Seal Replacement 9 12 Timing INSP CCU OMe ET m UU ULL 9 13 Se m Em 9 15 Camshat INCIMOVAl A 9 15 9 16 GalMshialt Inspectloliussenouedsnvos tris rente 9 17 Cranksnat andi Connecting ROS od eme a Dd t 9 18 Connecting IRGIMOV All Lia bd 9 18 Connecting Rod Maii cile etr E 9 18 CrankshatbiseimoValucsese ioco aspe a idees ea ii oa Do emer doses 9 19 Cranksna IsiallaGnes facete dete a 9 19 Connecting Rod Big End Side Clearance 9 20 Connecting ROG e ern me ne EN cat Site a reb tia ua tud deua 9 21 Crankshaft INS POC ON c opa td ran crc dd heit Pt 9 21
136. 5 ft Ib Olnstall the front A and rear seat belts so that their instal lation angle 15 40 60 B e Tighten Torque Seat Buckle Mounting Bolts 34 3 5 25 ft lb Olnstall the front seat belt buckles A so that their red but tons B face inside FRAME 16 15 16 16 FRAME Control Panel Control Panel Removal e Remove Front Cargo Compartment see Front Cargo Compart ment Removal e Remove the bands A and clamp B and free the leads e Disconnect Light Switch Lead Connector C Oil Pressure Warning Glow Plug Indicator Light Lead Connector D Speedometer Illumination Light Lead Connector E Coolant Temperature Warning Parking Brake Indicator Light Lead Connector F Power Steering Warning Light Lead Connector G Hour Meter Lead Connector H Main Switch Lead Connector I Power Outlet Connector Lead Connector J Fuel Gauge Hour Meter Lead Connectors K L KAF950G9 GC HA M KAF950GD e Disconnect the horn switch lead connectors A KAF950GD e Remove Bolts A opeedometer Cable Upper End B Speedometer C with Bracket FRAME 16 17 Control Panel e Remove the steering wheel see Steering Wheel and Steering Shaft Removal in the Steering chapter e Remove the control panel mounting screws A and col lars e Open the glove compartment covers A e Remove the control panel B Control Panel Installation e Installation is the reverse of removal note the
137. 55 mm 1 4138 1 4155 in Left Side C 35 910 35 955 mm 1 4138 1 4155 in Service Limit Right Side A 35 89 mm 1 413 in Center B 35 84 mm 1 411 in Left Side C 35 84 mm 1 411 in e Measure the camshaft runout x If the measurement exceeds the service limit replace the camshaft Camshaft Runout Service Limit 0 03 mm 0 0012 in 1105001851 9 18 CRANKSHAFT CRANKCASE Crankshaft and Connecting Rods Connecting Rod Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Valve Lifters see Valve Lifter Removal in the Engine Top End chapter Oil Pan see Oil Pan and Oil Strainer Removal in the Engine Lubrication System chapter e Remove the carbon to prevent damaging the piston rings or piston NOTE ONumber the connecting rod piston assemblies before removing e Remove Connecting Rod Cap Nuts A Connecting Rod Cap B e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder e Reassemble the connecting rod cap to the connecting rod to prevent interchanging components Connecting Rod Installation e Install the connecting rod bearing inserts OBe sure tang A on the bearing inserts are seated in the notches in the connecting rod and cap Install a piece of vinyl tubing B over each connecting rod threads to prevent damage
138. 55 mm 35 84 mm 1 4138 1 4155 in 1 411 in Left Side 35 910 35 955 mm 35 84 mm 1 4138 1 4155 in 1 411 in Camshaft Runout 0 03 mm 0 0012 in Crankshaft and Connecting Rods Connecting Rod Big End Side 0 15 0 28 mm 0 3 mm Clearance 0 0059 0 0110 in 0 0118 in Connecting Rod Small End Inside Diameter 18 03 mm 0 7098 in Connecting Rod Big End Out of Round 0 02 mm 0 0008 in Connecting Rod Thrust Faces Distortion 0 05 mm 0 0020 in Crankshaft Main Journal Diameter 41 976 42 000 mm pu 1 6526 1 6535 in Crankshaft Crankpin Diameter 36 976 37 000 mm Se 1 4557 1 4567 in Crankshaft Out of Round and Taper 0 02 mm 0 0008 in Undersize Crankshaft Main 0 25 mm 0 0098 in Undersize Bearing Inserts Crankshaft Z3 Main Journal Runout 0 06 mm 0 0024 in Crankshaft Side Clearance 0 02 0 24 mm 0 30 mm 0 0008 0 0094 in 0 0118 in Oversize Thrust Washers 0 12 mm 0 0047 in Oversize CRANKSHAFT CRANKCASE 9 5 Specifications tem _ Standard Crankshaft 3 Main Journal Width 122 00 22 07 mm 0 8661 0 8699 in Connecting Rod Big End Bearing 0 020 0 044 mm 0 07 mm Insert Crankpin Clearance Crankshaft Main Bearing Insert Journal Clearance Pistons and Crankcase Crankcase Warp 0 0008 0 0017 in 0 0028 in 0 020 0 044 mm 0 07 mm 0 0008 0 0017 in
139. 6 13 Seats and Seat Belts e When replacing the rear handle pad A install it on the seat bar B with adhesive agent OApply adhesive cement to 3 places Both ends and center Length 80 mm 3 15 in Slit C e Install the cover D so that its velcro side E faces down ward Rear Seat Removal e Fold the rear seat and push its assembly into the stored position e ilt up the cargo bed e Remove Pivot Bolt A Nut B Washers C Rear Seat D e Remove Rear Seat Back Mounting Nuts A Rear Seat Stay B Rear Seat Back C e Remove Bottom Lever Bolts A Bottom Lever B with Upper Lever C e Remove the circlip A 16 14 FRAME Seats and Seat Belts e Remove Left Side only Circlip A Spring B and Pin C e Separate the upper lever from the bottom lever Rear Seat Installation e Installation is the reverse of removal note the following OReplace the removed nuts with new ones Olnstall the rear seat back A so that its thicker side B faces upward Seat Belt Removal e Remove Front Seat Belt Mounting Bolts A Front Seat Belts B e Remove Front Seat Belt Buckle Mounting Bolts A Front Seat Belt Buckles B e Remove Rear Seat Belt Mounting Bolts A Rear Seat Belts B Seats and Seat Belts e Remove Rear Seat Belt Buckle Mounting Bolts A Rear Seat Belt Buckles B Seat Belt Installation e Tighten Torque Seat Mounting Bolts 34 N m 3 5 2
140. 64 Speed Sensor Installation 17 65 17 2 ELECTRICAL SYSTEM Speed Sensor Inspection 17 65 Ric EDI EE 17 66 Fuse Remowval 17 66 Fuse Installation 17 66 50 A Fuse Removal Fuse Installation Fuse Inspection ELECTRICAL SYSTEM 17 3 This page intentionally left blank 17 4 ELECTRICAL SYSTEM Exploded View 1002021BW5 ELECTRICAL SYSTEM 17 5 Exploded View a Nol Femme Aternator Adjusting Bracket Bois 20 20 18 _ 2 Aerator Mounting Bot 39 40 29 3 Alternator Pulley Locknut n 11 4 Starter Motor End Cover Screws 15 06 Sin Starter Motor Mounting Bos s 40 29 _ 6 Starter Motor Through Bots 095 G Apply grease R Replacement Parts 17 6 ELECTRICAL SYSTEM Exploded View 19092081885 ELECTRICAL SYSTEM 17 7 Exploded View Nol BateyHoderMow ngNus 17 19 2 ComecmgPlae Nus 12 012 Mimb v 5 Neutral Switch e 18 M 6 Pressure Switch 4 14 1 SS 7 Radiator Fan Swin 23 Radiator Fan Swin 25 28 186 9 KAF950G9 GC HA Other than US Model E Fuel Cut Solenoid Connector 11 Glow Plug Relay
141. 8 0 kgf m 58 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole SUSPENSION 14 11 HJ07007BS1 14 12 SUSPENSION Front Suspension Arms e Bend the cotter pin A over the nut B Front Suspension Arm Inspection e Visually inspect the front suspension arm for breaks or distortion x If the front suspension arm is damaged in any way re place it e Check the rubber bushings in the pivots x Replace any bushings that are worn cracked hardened or otherwise damaged J04109BS1 SUSPENSION 14 13 Leaf Springs and Dampers Leaf Spring Removal e Remove the rear wheel see Wheel Removal in the Wheels Tires chapter e Hold the rear brake drum and panel assembly in position e Free the brake hose A pipe and cable from the leaf spring Olmmediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove Rear Shock Absorber B Damper Bracket Mounting Nuts C and Leaf Spring Bracket Damper and Bracket D e Remove Bolt A Clamp B Leaf Spring Mounting Bolt and Nut C e Remove Leaf Spring Mounting Nuts A Leaf Spring B
142. 81 EPS Torque Sensor Inspection Service Code 51 e urn the main switch OFF e Disconnect the EPS torque sensor connector e Set the hand tester to the x 1O range and connect it to the EPS torque sensor connector Special Tool Hand Tester 57001 1394 e Measure the EPS torque sensor resistance EPS Torque Sensor Resistance Inspection Connections 1 Y R Lead lt gt BK BL Lead C Lead D BK BL Lead C 1008017881 Standard Both Connections Any Reading Resistance reference 10 40 at 20 68 F x If the reading is infinity replace the EPS unit see EPS Unit Removal Installation 15 44 STEERING EPS Electric Power Steering System x If the reading is in specification disconnect the EPS ECU connectors and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector A lt gt EPS Torque Sensor Connector B YIBK Lead C YIR Lead D BK BL Lead E x If the wiring is good check the power supply voltage see EPS ECU Power Supply Voltage Inspection xIf the power supply voltage is good erase the service code with the service code erase mode and enter the self diagnosis mode again x If the service code 51 appears again replace the EPS ECU see EPS ECU Removal Installation x If the service code 51 disappears it is a temporary failure EPS Mot
143. 910 57001 1435 T570910ST T5714358T 6 Piston Ring Compressor Grip Timing Gear Cover Oil Seal Driver 57001 1095 57001 1436 5757109557 875714368 Piston Ring Compressor Belt 50 67 Retainer Oil Seal Driver 57001 1096 57001 1437 T5710968T 875714378 6 CRANKSHAFT CRANKCASE 9 7 Special Tools Flywheel Holder 57001 1438 9 8 CRANKSHAFT CRANKCASE Timing Gear Case Timing Gear Case Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Fan Belt see Alternator Removal in the Electrical Sys tem chapter e Using the flywheel holder A hold the crankshaft Special Tool Flywheel Holder 57001 1438 e Remove the crankshaft pulley bolt A e Remove the crankshaft pulley A Special Tools Crankcase Splitting Tool Assembly 57001 1098 Bearing Puller Adapter C 57001 136 e Remove Oil Pan and Oil Strainer see Oil Pan and Oil Strainer Removal in the Engine Lubrication System chapter Timing Gear Case Cover Bolts A Timing Gear Case Cover B Bracket C e Temporary install the flywheel for the crankshaft holding OUsing the flywheel holder A hold the crankshaft Special Tool Flywheel Holder 57001 1438 CRANKSHAFT CRANKCASE 9 9 Timing Gear Case e Remove Gear Nut A Gear Bolts B Oil Pump Drive Gear C Camshaft Drive Gear D e Position the flywheel holder to the opposite side e Remove Idle Gear Bolts E
144. A Cap B e Remove the air cleaner element A e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the torque converter NOTICE If dirt gets into the torque converter excessive wear and loss of driving power may result Air Cleaner Element Cleaning Inspection e Refer to the Converter Air Cleaner Element Cleaning In spection in the Periodic Maintenance chapter Torque Converter Torque Converter Outer Cover Removal e Lift up the cargo easy to work e Remove Converter Air Cleaner Housing see Air Cleaner Housing Removal Left Rear Wheel see Wheel Removal in the Wheels Tires chapter Flap Stay see Flap and Flap Stay Removal in the Frame chapter Left Rear Shock Absorber see Rear Shock Absorber Removal in the Suspension chapter Screws A Cover B e Remove Converter Cover Bolts A and Collars Torque Converter Outer Cover B Torque Converter Outer Cover Installation e Install the outer cover A as shown in the figure OFirst insert the rear side B of the outer cover in the frame e Install the collars and converter cover bolts e Tighten Torque Converter Cover Bolts 4 4 N m 0 45 kgf m 39 Torque Converter Inner Cover Removal e Remove Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Torque Converter Outer Cover see Torque Converter Outer Cover Removal Drive Pulley see Drive Pulley Re
145. A so that the mark F Arrow B faces forward e Install the upper universal joint A to the shaft of the EPS unit B e Install the universal joint clamp bolt lower C while align ing the notch on the shaft of the EPS unit with the clamp bolt hole on the upper universal joint and tighten it tem porary e Install the steering shaft D to the upper universal joint e Install the universal joint clamp bolt upper E while align ing the notch on the steering shaft with the clamp bolt hole on the upper universal joint and tighten it temporary e Install the steering shaft mounting bolts F washers and nuts H e Tighten all the universal joint clamp bolts to the specified torque Torque Universal Joint Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib e Install the washer KAF950GD J KAF950G9 GC HA 1005011 82 1008092832 EPS Electric Power Steering System e Mount the steering wheel on the steering shaft temporar e Adjust the following items Steering Wheel Position see Steering Wheel Position Adjustment Steering Wheel Centering see Steering Wheel Center ing e nstall the removed parts see appropriate chapters e Be sure to register the EPS neutral position see EPS Neutral Position Registration Speed Sensor Removal Installation e Refer to the Speed Sensor Removal Installation in the Electrical System chapter Speed Sensor Inspection e Refer to the Speed Sensor Inspecti
146. APPENDIX 18 9 Cable Wire and Hose Routing ae cell eai Ij Lau 1808091894 C Differential Shift Cable 2WD AWD Shift Cable Hi Low Shift Cable Transmission Shift Cable Throttle Cable Clamp To Engine Nut Torque Converter Case Torque Converter Inner Cover Front 12 Viewed from Top 18 10 APPENDIX Cable Wire and Hose Routing KAF950G9 Early Model 18081568484 1 Breather Tube L 1 480 mm 58 3 in 2 Brake Hose 3 Coolant Reserve Tank 4 Band 5 Clamp 6 Brake Pipe T Front 8 Route cooling hose under frame pipe 9 Pass the cooling hose through the hole of the bracket on the frame APPENDIX 18 11 Cable Wire and Hose Routing KAF950G9 Late Model and Later Model 18082168884 Breather Tube 1 100 mm 43 3 in Brake Hose Push the tube into the hole of case storage Clamp Band Front 18 12 APPENDIX Cable Wire and Hose Routing 18080948484 Right Brake Drum Right Frame Breather Tube Brake Pipe Brake Cable Left Brake Drum Left Frame Band po o c Cable Wire and Hose Routing KAF950G9 GC HA APPENDIX 18 13 1 Right Parking Brake Cable 2 Left Parking Brake Cable 3 Clamp 4 Rubber Tube 5 Cap 6 Washer 7 Left Brake Hose 18080878484 8 Right Brake Hose 9 Right Leaf Spring 10 Left Leaf Spring 11 50 mm 1 9 in 12 Band 13 Front 14
147. Ah Engine Ground Terminal BR Radiator Fan Relay Alternator BK BL BL LIGHT SWITCH CONNECTIONS Color 0 Y ON START W2LO756AWS ELECTRICAL Wiring Diagram KAF950GD EPS EGU EPS W gt arning Indicator Light LED 1 Work Lamp 12V55W 2 Socket 3 Back up Beeper 1 4 Wiper 358004 Warning Light EPS 6 Cargo Bed Light gt xt G o uu Fuse tok 5 40 tn m e 69 x 1 EPS ECU Relay Diodes 5 e ex 1 1 1 Dr 1 1 1 25 e 1 gt Ja r5 Fuse zx m 7 EPS Motor EPS Torque EPS R Y T9 Sensor Self diagnosis System Speed jj Connector Sensor SYSTEM 17 17 for Example Starter Circuit Relay l l BK W R W Europe Model i HILL BK Y BL R BK Y Injection Le x m Pump NN Glow Plug Relay Fuse Box 1 m KIM Fusible 9 Link 50A Fuse Box 2 0 BK W 55 5 Fuse Box 1 x 1 ns 1 Starter Relay Fuse 30 ot 3 2 ccessory Conector Fuse 20 Preheating Starter 3 Accessory Fuse 20 Timer Motor 2 puse BOX 2 011 Coolant 1 Fuse 30A PressureTemperature 2 Horn Fuse Switch Switch 3 Preheating Timer Fuse NEUTRAL SWITCH CONNECTIONS
148. C of the duct e Install the air ducts B and tighten the clamp screws 24 M d e Install the air cleaner housing A as shown in the figure Approximately 60 B Inside C e Tighten Torque Air Cleaner Housing Mounting Bolts 20 N m 2 0 kgf m 15 ft Ib Air Cleaner Housing Dust and or Water Inspection e Push open the drain tube A on the bottom of the air cleaner housing Fuel Filter Fuel Filter Removal e ilt up the cargo bed e Remove Clamp A Fuel Hose B Fuel Filter Mounting Bolts C e Remove Clamp A Fuel Hose B Fuel Filter C Fuel Filter Installation e Install Fuel Filter Fuel Hoses see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Fuel Filter Mounting Bolts 20 2 0 15 ft Ib e Bleed the air from the fuel filter OLoosen the air vent plug A OPump the priming button B until the fuel comes out of the air vent OTighten the air vent plug securely Torque Air Vent Plug 5 0 N m 0 51 kgf m 44 in Ib OWipe up any spilled fuel e Start the engine and check for fuel leakage Fuel Filter Cartridge Replacement e Refer to the Fuel Filter Element Replacement in the Peri odic Maintenance chapter Water Draining e Refer to the Fuel Filter Water Draining in the Periodic Maintenance chapter FUEL SYSTEM 3 31 3 32 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Fuel is extremely
149. C the lever D of the shift shaft to lib e Fit the shift arm pins A into the shifter grooves B and install the hi low gear case e Tighten Torque Hi Low Gear Case Bolts 20 N m 2 0 kgf m 15 ft Ib 10 24 TRANSMISSION Hi Low Gears and Shift Mechanism e Install the retaining pin A e Replace the O ring B with a new one e Apply grease to the new O ring and install the holder C e Tighten the bolt D e Check that each gear and shifter spins or slides freely on its shaft without binding after assembly 1J07002BS1 Hi Low Gear and Shift Mechanism Inspection e Visually inspect the hi low gears shifter and low gear bushing If they are damaged or worn excessively replace them e Replace parts worn beyond the service limit Shifter Block Outside Diameter A Standard 13 95 14 00 mm 0 549 0 551 in Service Limit 13 8 mm 0 543 in Shifter Groove Width B Standard 14 05 14 15 mm 0 553 0 557 in Service Limit 14 3 mm 0 563 in 2WD AWD Shift Mechanism 2WD 4WD Shift Cable Adjustment e Put the shift lever A in the 2WD position e Install the 2WD AWD shift cable A to the shift shaft lever B and cable bracket C e Put the shift lever A in the 4WD position e urn the shift shaft lever A counterclockwise until the lever is stopped by engaging the shifter with the drive bevel gear shaft e Screw in the upper adjuster nut B by hand until the inner
150. Drive Belt Deflection Inspection e Remove the torque converter inner cover see Torque Converter Inner Cover Removal in the Converter System chapter e Putthe transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley e Measure the belt deflection as shown in the figure a straightedge A on top of the belt between the drive pulley B and the driven pulley C OUse a ruler to push the belt away from the straightedge Push hard but with no more force than 59 N 6 kgf 13 Ib Belt Deflection Standard 28 36 mm 1 10 1 42 in the belt deflection is not within the specified range first measure the drive belt width see Drive Belt Inspection Adjust the deflection by adding or removing spacers be tween the driven pulley shaft hub and cam ramp e When adjusting the deflection less is better than more Less deflection will maintain better performance for more time as the belt width decreases by normal wear which causes the deflection to increase with usage 2853 1 05003 81 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Drive Belt Deflection Adjustment e Disassemble the driven pulley A see Driven Pulley Dis assembly in the Converter System chapter x If the belt deflection is more than 36 mm 1 42 in remove Pm the spacers to decrease it OThe rule of thumb is 0 1 0 004 in change
151. HeadBos 34 38 25 EOS 2 54 oss bm 3 Exhaust Manifold Mounting Nuts 20 20 18 4 Inlet Manifold Mounting Bots 78 080 enb 75 metManfodMouningNus 78 080 emb 6 Rocker Arm Components Mounting Nuts 20 20 18 T Valve Adjusting Screw Locknuts M 11 onb 78 Mutter Mounting Bots 20 15 ti EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 5 Follow the specified tightening sequence 5 4 ENGINE TOP END Specifications Wem Standard Cylinder Head Cylinder Compression 330 kPa 34 0 kgf cm 2 990 kPa 30 5 kgf cm 483 psi at 300 r min rpm 434 psi at 300 r min rpm Cylinder Head Warp 0 1 mm 0 004 in Rocker Shaft and Rocker Arm Rocker Arm Inside Diameter 10 00 10 02 mm 10 03 mm 0 3949 in 0 3937 0 3945 in Rocker Shaft Diameter 9 97 9 99 mm 9 957 mm 0 3920 in 0 3925 0 3933 in Valve Lifters Valve Lifter Outside Diameter 17 98 mm 0 7079 in 17 91 mm 0 7051 in Valves Valve Clearance 0 20 mm 0 0079 in Valve Seating Surface Width 0 8 1 2 mm 0 0315 0 0472 in Outside Diameter Inlet 28 mm 1 1024 in Exhaust 24 5 mm 0 9646 in Valve Seat Cutting Angle 32 45 60 Valve Spring Free Length 30 7 mm 1 2087 in 29 7 mm 1 1693 in
152. If the bearing has worn past the service limit replace the rocker arm Rocker Arm Inside Diameter Standard 10 00 10 02 mm 0 3937 0 3945 in Service Limit 10 03 mm 0 3949 in 05007 81 5 12 ENGINE TOP END Rocker Shaft and Rocker Arm e Measure the diameter A of the rocker shaft x If the shaft has worn past the service limit replace the rocker shaft Rocker Shaft Diameter Standard 9 97 9 99 mm 0 3925 0 3933 in Service Limit 9 957 mm 0 3920 in EO5008BS1 Valve Lifters Valve Lifter Removal e Remove Cylinder Head see Cylinder Head Removal Valve Lifters A OMark and record the valve lifter locations so that they can be installed in their original positions Valve Lifter Installation e Apply engine oil and install the valve lifters original posi tions Valve Lifter Inspection e Measure the outside diameter of the valve lifters A x If the valve lifter has worn past the service limit replace the lifter Valve Lifter Outside Diameter Standard 17 98 mm 0 7079 in Service Limit 17 91 mm 0 7051 in ENGINE TOP END 5 13 05004 81 5 14 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove Cylinder Head see Cylinder Head Removal Valve
153. Illumination 12 1 78 Gil Pressure Warning Indicator Light 12V1 7W BR Glow Plug Light 12V1 7W PE Coolant Temperature Warning Indicator Light 12V3W c v HH Parking Brake Indicator Light i2V3W HH Light R G BK Y Switch T b OETTON TIEN Eee e BK N H H4 H mM a BL R Parking Brake Light Switch Main Switch i H Terminals lt 6 lt R W BL O W R E 12V35WX2 BK Y 4 R BK BK Y Steering Shaft Component Engine Brake Light Ground Switch BEEN BL Terminal e BR l BK Y Radiator Fan Relay Horn C Alternator Horn Button Battery 12V52Ah Steering Gear Assembly rad Radiator Fan Switch CBE R R Radiator Fan ome MAIN SWITCH CONNECTIONS Color BK YW BKBK W BR W E o LE R BK BK Y Headlights LIGHT SWITCH CONNECTIONS 0o Y Eo W2LO360BWS C ELECTRICAL SYSTEM 17 13 Wiring Diagram KAF950G9 GA HA Starter Circuit Optional Parts for Example 71 Relay 1 Work Lamp 12V55 d 2 Socket in 3 Back up Beeper Te
154. KES 13 7 Special Tools Clutch Spring Compressor Brake Drum Holder 57001 1162 57001 1325 875711628 875713255 Rotor Puller M16 M18 M20 M22 x 1 5 Brake Drum Remover Nuts 57001 1216 57001 1326 875712165 875713268 Brake Drum Remover Grease Seal Driver Set 57001 1260 57001 1629 T5712608T T5716298T Brake Drum Pusher M18 x 1 5 57001 1261 875712618 13 8 BRAKES Brake Fluid Brake Fluid Recommendation e Use extra heavy duty brake fluid only from a container marked DOTS Recommended Brake Fluid Type DOT3 AWARNING Brake fluid that is contaminated by moisture or dirt mixed or contains air has a lower boiling point and can cause the brake to be ineffective or fail and it may cause rubber parts to deterioate resulting in an accident causing injury or death Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake Don t leave the reser voir cap off for any length of time to avoid moisture contamination of the fluid Don t add or change the fluid in the rain or when a strong wind is blowing If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately B
155. Length Projected 10 5 mm 0 41 in 8 4 mm 0 33 in Portion Electric Starter System Starter Motor Carbon Brush Length 15 5 mm 0 61 in 11 0 mm 0 43 in Commutator Diameter 30 mm 1 18 in 29 mm 1 14 in Preheating System Glow Plug Resistance About 0 1 5 0 0 Meter Gauge Fuel Level Gauge Resistance Full Position 90 110 Empty Position 119 1210 Switches and Sensors Brake Light Switch Timing ON after 10 mm 0 39 in of pedal travel Radiator Fan Switch Resistance Rising Temperature From OFF to ON at 86 90 C 187 194 F Falling Temperature From ON to OFF at 81 85 178 185 F ON Less than 0 5 O OFF More than 1 MO Specifications Coolant Temperature Switch Resistance Rising Temperature Falling Temperature ELECTRICAL SYSTEM 17 19 From OFF to ON at 112 118 C 234 244 F From ON to OFF within 10 C 50 F of ON temperature ON Less than 0 5 O OFF More than 1 MO 17 20 ELECTRICAL SYSTEM Special Tools Socket Wrench Hex 22 Hand Tester 57001 1236 57001 1394 8757139845 875712368 ELECTRICAL SYSTEM 17 21 Parts Location Hour Meter A Main Switch B Power Outlet Connector C Fuel Gauge Hour Meter D E KAF950G9 GC HA F KAF950GD Light Switch A Oil Pressure Warning Indicator Light B Coolant Temperature Warning Indicator Light C Speedometer D Parking Brake Indicator Light E Glow Plug Light F Horn Button
156. ODIC MAINTENANCE Specifications tem Standard Brakes Brake Fluid Type DOT3 Fluid Level Between upper and lower level lines Brake Pedal Play 2 10 0 08 0 39 in Brake Drum Inside Diameter 180 000 180 160 mm 180 75 mm 7 0866 7 0929 in 7 116 in Brake Shoe Lining Thickness 4 5 mm 0 18 in 1 0 mm 0 04 in Parking Brake Lever Travel 8 12 notches clicks at 200 20 kgf 44 Ib Steering Steering Wheel Free Play 0 20mm 0 0 79 in Electrical System Battery Capacity 12 V 52 Ah Voltage 12 6 V or more Electrolyte Level Between upper and lower level Specific Gravity 1 265 at 20 C 68 F Switches Brake Light Switch Timing ON after 10 mm 0 39 in of pedal travel Conventional Type Battery PERIODIC MAINTENANCE 2 13 Special Tools Inside Circlip Pliers Flywheel amp Pulley Holder 57001 143 57001 1605 875701435 ST5716058T 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Pedal Play Inspection e Check that the throttle pedal moves smoothly from full open to close x If the throttle pedal does not return properly lubricate the throttle cable and link see Throttle Cable Lubrication in the Fuel System chapter e Check the throttle pedal play A Throttle Pedal Play Standard 5 10 mm 0 20 0 39 in x If the play is incorrect adjust the throttle cable Throttle Ped
157. OLATION 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 inlet 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 Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to 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 before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and
158. OTE OThe fluid level must be checked several times during the fluid changing and replenished as necessary If the fluid in the reservoir runs completely out any time during fluid changing air bleeding must be done since air will have entered the line e Remove the wheel for extra clearance see Wheel Re moval in the Wheels Tires chapter e Remove the reservoir cap e Remove the rubber cap from the bleed valve on the wheel cylinder e Connect a clear plastic hose A to the bleed valve at the wheel cylinder running the other end of the hose into a container Left Front Brake Panel B NOTE OStart with the rear left or right wheel and finish with the front left or right wheel 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fill the reservoir with new brake fluid e Temporarily install the reservoir cap e Change the brake fluid as follows 1 Open bleed valve 2 Pump brake pedal and hold it 3 Close bleed valve 4 Release brake pedal e lighten Torque Bleed Valves 5 4 N m 0 55 kgfm 48 in Ib e Repeat the previous step for each wheel e When brake fluid changing is finished add the fluid to the upper level in the reservoir e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage If necessary bleed the air from the brake lines see Brake Line Air Bleeding in the Brakes chapter WARNING Air in the brake lines diminish braking pe
159. Olnstall the holder so that the short side C of the holder faces forward e Tighten the battery holder mounting nut D lightly e Put the battery on the case so that the positive terminal A faces right side e Install Battery Holder B Battery Holder Rod Rear Side Pipe C and Nut D e Tighten Torque Battery Holder Mounting Nuts 17 N m 1 7 kgf m 13 ft lb e Connect the four leads on the positive lead connector A as shown in the figure Red White Red B Blue White C Black White D Red Alternator Lead E Olnstall the four leads almost parallel to the positive cable so that they can be covered with the cap easily e Connect the positive cable and leads first and then connect the negative cable and lead black and black yellow e Put a light coat of grease on the terminals to prevent cor rosion e Cover the positive terminals with the positive terminal COVer 1008014851 Battery for Sealed Type Battery e Confirm the position of the battery handle A is below the holder B and cables C as shown in the figure Electrolyte Level Inspection Conventional Type Battery e Refer to the Electrolyte Level Inspection Conventional Type Battery in the Periodic Maintenance chapter Electrolyte Specific Gravity Inspection Conventional Type Battery e Refer to the Electrolyte Specific Gravity Inspection Con ventional Type Battery in the Periodic Maintenance chap ter Chargin
160. Pipe Nuts E Torque Linkage Pipe Nuts 27 2 8 kgfm 20 ft Ib POTRO e Install Fuel Return Hose Fuel Injection Pipes see Fuel Injection Pipe Installation Fuel Injection Nozzle Inspection A WARNING Fuel is released from the injection nozzle at high pressure and is highly flammable Keep hands fin gers and other body parts at least 12 inches from the nozzle during testing Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTE ORefer to the Fuel Injection Pump Inspection and Repair for nozzle repair information Fuel Injection Nozzle Injection Pressure Check e Install the fuel injection nozzle on a nozzle tester e Quickly move the tester lever up and down so that the injection nozzle sprays two to three times OThis step blows off any carbon deposits on the injection nozzle port e Move the lever very slowly gradually raising the pressure e Measure the maximum pressure just as the pointer of the pressure gauge drops suddenly Fuel Injection Nozzle Injection Pressure Marking of Injection Nozzle Red or Green 13 239 14 220 kPa 135 145 kgf cm 1 920 2 062 psi None 14 465 14 955 kPa 147 5 152 5 kgf cm 2 098 2 169 psi x If the measured pressure does not comply with the spec ification replace the injection nozzle Leakage Check When there is a mark green or red on the nozzle
161. Power Steering System Service Code Erasing Procedures NOTE OKeep the self diagnosis system connector terminals connected during service code erase mode with an auxiliary lead OThe EPS motor does not operate during service code erase mode e Start the service code erase mode with the following pro cedure OFirst turn the main switch OFF OSecond connect an auxiliary lead to the terminals of the EPS self diagnosis system connector by the same pro cedure as self diagnosis mode see Self diagnosis Pro cedure OThird lift the front wheel off the ground OFourth turn the steering wheel fully to the left and keep it OFifth start the engine while turning the steering wheel fully to the left OThe EPS warning indicator light LED ights up for 4 sec onds and goes off x If the service code is indicated turn the main switch OFF and repeat from fourth procedure again OSixth free the hands from the steering wheel after indica tor light goes off OAfter 4 seconds the EPS warning indicator light LED lights up OSeventh turn the steering wheel fully to the left and keep it after indicator light lights up OAfter 4 seconds the EPS warning indicator light LED goes off OEighth free the hands from the steering wheel after indi cator light goes off OAfter 4 seconds the EPS warning indicator light LED blinks two times This blink shows that the service code was erased x If the EPS warning indicator light LED
162. Race A Cage B Inboard Joint Boot C Inboard Joint Boot Installation e Install New Small Band A New Inboard Joint Boot B Cage C e Install the inner race A so that the flat serration side B faces outboard joint 1078077 e Install Circlip A Special Tool Outside Circlip Pliers 57001 144 e Slide the cage B on the inner race and install the steel balls C e Apply the special grease A to the steel balls and cage FINAL DRIVE 12 41 Drive Shaft and Axles e Squeeze about half a tube 30 grams of the special grease A into the bearing cup B e Insert the balls and cage assembly in the bearing cup strongly e Install the axle shaft A into the bearing cap B e Install the new retaining ring A so that the opening B is aligned with one of the projections C HK10004B31 e Squeeze the remaining special grease into the bearing cup A and new joint boot B e Pinch the small boot band A with a suitable tool B to install it 12 42 FINAL DRIVE Drive Shaft and Axles e Compress the axle assembly to the specified length while relieving the air pressure inside the boot e Hold the axle at this setting Standard Length of Assembling Outboard 210 3 mm 8 280 in A OSlightly open A the larger diameter end of the joint boot to equalize the air pressure inside the boot e Pinch the boot bands A with a suitable tool B to install them OCompress the suitabl
163. S ECU STEERING 15 49 EPS Electric Power Steering System EPS ECU Power Supply Voltage Inspection e Remove the band and open the cover see EPS ECU Removal e Visually inspect the EPS ECU connectors A x If the connector is clogged with mud or dust blow it off with compressed air x If the connectors are normal check the terminals of the EPS ECU connectors e urn the main switch OFF e Disconnect the EPS ECU connectors e Visually inspect the terminals of the EPS ECU connectors main harness and EPS ECU If the terminals of the main harness connectors are dam aged replace the main harness x If the terminals of the EPS ECU connectors are damaged replace the EPS ECU x If the terminals are normal measure the power supply voltage of the EPS ECU NOTE OBe sure the battery is fully charged e Set the hand tester A to the DC 25 V range and connect it to the main harness connectors B Special Tool Hand Tester 57001 1394 EPS ECU Power Supply Voltage Inspection Connections Hand Tester gt Lead Terminal C Hand Tester Battery Terminal Hand Tester Lead Terminal D Hand Tester gt Battery Terminal Main Switch OFF Connection 1 Battery Voltage Connection Il 0 V Engine Running Both Connections Battery Voltage x the reading is out of the specification check follow ing EPS Fuse 40 A see Fuse Inspection EPS Fuse 7 5 A s
164. Split ting e Remove Differential Gear Assembly see Differential Gear Re moval Drive Shaft A Washers B Drive Shaft Reverse Sprocket C Drive Chains D e Remove Shift Arm Positioning Bolt Assembly A Retaining Pin B e Lift the shift arm C and remove the shifter D e Remove Drive Shaft Outer A and Drive Shaft Forward Gear B Shifter Block C Shift Arm D Transmission and Shift Mechanism e Remove the driven shaft assembly A e Remove Circlips A Driven Shaft Reverse Sprocket B Driven Shaft Forward Gear C Driven Shaft D Special Tool Outside Circlip Pliers 57001 144 Transmission Installation e Replace all circlips that were removed with new ones NOTE OAlways install the circlips A so that the opening B is aligned with a spline groove To install a circlip without damage first fit the circlip onto the shaft C and then expand it just enough to install Hence use a suitable gear to push the circlip into place e Apply transmission oil to the following parts Drive and Driven Shafts Forward Gears Reverse Sprockets Drive Chains e Apply grease to the following parts Oil Seal Lips Shift Arm Positioning Ball and Spring e Install the shifter A so that the groove B is away from the forward gear C e Tighten Torque Shift Arm Positioning Bolt 37 N m 3 8 kgf m 27 ft Ib TRANSMISSION 10 19 10 20 TRANSMISSION Transmission and Shift Mechanism Tra
165. Steering wheel is too light Steering wheel is unbalance L Steering wheel is naturally turned to one side When operating the steering wheel make vibration or noise When operating the steering wheel the headlight darkens L EPS system does not operate Other Engine conditions at O At start up problem Driving conditions At high speed At low speed lights up immediately after engine starts and goes off after 1 second lights up immediately after engine starts and stays Blinks immediately after engine starts and stays Does not light up Sometimes lights up Phenomenon L After starting EPS warning indicator light LED conditions Self diagnosis Outline The EPS self diagnosis system has two modes and can be switched to another mode by connecting terminals of the EPS self diagnosis system connector A User Mode The EPS ECU notifies the rider of troubles in EPS system by lighting the EPS warning indicator light LED when EPS system parts are faulty and initiates fail safe function In this case EPS ECU stops the EPS motor operation Dealer Mode The EPS warning indicator light LED emits service code s to show the problem s by blinking EPS Electric Power Steering System Self diagnosis Procedure OWhen problem occurs with the EPS system the EPS warning indicator light LED A lights up NOTE OUse a fully charged battery when cond
166. Thrust Plate F Idle Gear G e Remove the idle gear shaft A e Using a suitable bearing puller B remove the fuel injec tion pump drive gear C e Remove the fuel injection pump D see Fuel Injection Pump Removal in the Fuel System chapter e Remove Camshaft Retainer Bolts A Camshaft Retainer B Timing Gear Case Bolts C Timing Gear Case D e Remove the oil pump outer rotor A Timing Gear Case Installation e Clean and lubricate the oil pump outer rotor A with en gine oil e Install the oil pump outer rotor with the punch mark B facing inside 9 10 CRANKSHAFT CRANKCASE Timing Gear Case e Install Dowel Pins A New Timing Gear Case Gasket B Timing Gear Case ORotate the oil pump shaft to engage oil pump rotors e Install the camshaft retainer A e Tighten Torque Camshaft Retainer Bolts 7 8 N m 0 80 kgf m 69 Timing Gear Case Bolts 7 8 N m 0 80 kgf m 69 28 mm 1 10 in B 18 mm 0 71 in C 16 mm 0 63 in D e Install the fuel injection pump temporarily e Align the marks A on the injection pump and the timing gear case e Install Fuel Injection Pump Drive Gear and Nut A Camshaft Drive Gear and Bolt OFace the timing marks B on the gears upward e Install the idle gear shaft C with the arrow D facing the engine top e Position the crankshaft key E upward top position e Install the idle gear so that the timing marks on the gears
167. U Power Source Wiring and Ground Wiring Speed Sensor When the repair has been done the EPS warning indi cator light LED lights up immediately after engine starts and goes off after 1 second This shows that EPS system is normal But service codes detected once by the EPS ECU will be memorized in the EPS ECU Therefore after main tenance work ends be sure to erase the service codes with service code erase mode Do not erase the service codes during troubleshooting Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work Before eras ing the service codes record them as problem history The problem history can be referred when solving unstable trou ble Even when the EPS system is operating normally the EPS warning indicator light LED may light up under strong electrical interference If the indicator light lights up turn the main switch OFF and then erase the service code Much of the EPS system troubleshooting work consists of confirming continuity of the wiring The EPS system parts are assembled and adjusted by the manufacturer so there is no need to disassemble or repair them Replace them as an assembly The basic troubleshooting procedures and precautions are listed below e Using a fully charged battery A fully charged battery is a must for conducting reliable self diagnosis function e Measure coil winding resistance when the EPS system
168. Valve Head Thickness 1 2 mm 0 0472 in 1 0 mm 0 0394 in Valve Stem Diameter Inlet 5 945 5 960 mm 5 903 mm 0 2324 in 0 2341 0 2346 Exhaust 5 965 5 980 mm 5 923 mm 0 2332 in 0 2348 0 2354 in Valve Guide Inside Diameter 6 000 6 015 mm 6 036 mm 0 2376 in 0 2362 0 2368 in Valve Guide Outside Diameter Standard Valve Guide 11 05 mm 0 4350 in Replacement Valve Guide 11 08 mm 0 4362 in Valve Guide Clearance Inlet 0 055 0 070 mm 0 090 mm 0 0035 in 0 0022 0 0028 in Exhaust 0 035 0 050 mm 0 094 mm 0 0037 in 0 0014 0 0020 in ENGINE TOP END 5 5 Special Tools Outside Circlip Pliers Valve Seat Cutter 60 230 57001 144 57001 1123 875701445 75711238T Valve Guide Arbor 55 5 Valve Seat Cutter Holder 55 5 57001 1021 57001 1125 Valve Seat Cutter 45 527 5 Valve Seat Cutter Holder Bar 57001 1114 57001 1128 Valve Seat Cutter 32 528 Compression Gauge Adapter 57001 1119 57001 1431 ST5711198T 875714318 6 Valve Seat Cutter 30 630 Valve Guide Driver 57001 1120 57001 1432 75711208T 875714328 5 6 ENGINE TOP END Special Tools Valve Spring Compressor 57001 1433 875714338 ENGINE TOP END 5 7 Cylinder Head Cylinder Compression Measurement e ilt up the cargo bed e horoughly warm up the engine so that the engine oil be tween the piston and the cylinder wal
169. View A 18 14 APPENDIX Cable Wire and Hose Routing KAF950GD 2 CA fi IL S a QS SESI S APPENDIX 18 15 Cable Wire and Hose Routing Right Parking Brake Cable Left Parking Brake Cable Clamp Rubber Tube Cap Washer Left Brake Hose Right Brake Hose Right Leaf Spring 10 Left Leaf Spring 11 50 mm 1 97 in 12 Band 13 Front 14 View A 15 Detail B 16 Corrugated Tubes 17 Install the corrugated tubes so that the slits face inside of the vehicle to prevent the breather tube and brake hose being damaged by the edges of the slit 18 30 mm 1 2 in 19 Tapes Fix the corrugated tubes on the parking brake cables 20 View C 21 70 mm 2 8 in 18 16 APPENDIX Cable Wire and Hose Routing 1 Speedometer Cable 2 Clamp the speedometer cable with the parking brake cable 3 Parking Brake Cable APPENDIX 18 17 Cable Wire and Hose Routing This page intentionally left blank 18 18 APPENDIX Cable Wire and Hose Routing E of APPENDIX 18 19 Cable Wire and Hose Routing 12 Shift Cable 14 15 16 17 18 Run the cables straight to front Trim Run the cables under the main harness and fuel hose Run the cables on the damper of right rear brake pipe
170. WD Shift Cable Lower End B Cable Bracket C e Remove Hi Low Gear Case Bolts A Hi Low Gear Case B e Remove Washer A High Gear B Washer Shifter C Reduction Gear D 10 22 TRANSMISSION Hi Low Gears and Shift Mechanism e Remove Circlip A Washer B Low Gear C Collar Special Tool Outside Circlip Pliers 57001 144 e Remove Bolt A Holder B e Remove Retaining Pin A shift Shaft and Arm B Hi Low Gear and Shift Mechanism Installation e Apply transmission oil to the following parts Hi Low Gears Shifter e Apply grease to the oil seal lips e Replace the circlip that was removed with a new one NOTE OAlways install the circlip A so that the opening B is aligned with a spline groove To install a circlip without damage first fit the circlip onto the shaft C and then expand it just enough to install Hence use a suitable gear to push the circlip into place 1J07003BS1 TRANSMISSION 10 23 Hi Low Gears and Shift Mechanism e Install the shifter A so that the large dogs B face to the low gear C e Install Reduction Gear Washer A e Install the high gear B so that the small gear side C faces shifter side e Replace the hi low gear case gasket A with a new one e Install Washer B Shifter C e Check to see that the hi low gear case dowel pins D are in place on the transmission case e nsert the shift shaft A in the gear case B e ouch
171. ace repair as necessary Cylinder Head Removal e Remove Water Pump see Water Pump Removal Fuel Injection Pipes see Fuel Injection Pipe Removal in the Fuel System chapter Exhaust Pipe see Exhaust Pipe Removal Rocker Arm Components see Rocker Arm Components Removal 5 8 ENGINE TOP END Cylinder Head e Remove Bolts A and Nuts Engine Mount Stay B Bolts C Cil Level Gauge Pipe D Bolts E Plate F e Remove Glow Plug Caps A Glow Plug Lead B Glow Plug Connecting Plate C Rocker Arm Push Rods D Valve Stem Caps E OMark the push rods so that they may be installed in their original positions e Remove the coolant from the cylinder head using a syringe A or some other suitable device through the coolant inlet opening B Olnsert the gauge tube C 10 11 cm 3 9 4 3 in from the opening OPull the handle slowly to pump out the coolant until the coolant no longer comes out e Remove the cylinder head bolts following loosening se quence 1 14 e Remove Cylinder Head gt X Cylinder Head Gasket L Cylinder Head Installation e Clean the mating surface of the cylinder head and the cylinder e Replace the cylinder head gasket A with a new one e Install the dowel pins B ENGINE TOP END 5 9 Cylinder Head e Apply engine oil to the cylinder head bolts e Tighten the cylinder head bolts in the order shown Torque
172. ach 10 C 50 F below 20 C 68 F OFahrenheit Add 0 004 points to reading for each 12 C 10 F above 20 C 68 F or subtract 0 004 points for each 12 C 10 F below 20 C 68 F x If the specific gravity of any of the cells is more than 0 050 away from any other reading the battery will probably not accept a charge It is generally best to replace a battery in this condition x If the specific gravity of all the cells is 1 265 or more the battery is fully charged 1818005 81 PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Charging Condition Inspection Conventional Type Battery OBattery charging condition can be checked by measuring battery terminal voltage e Disconnect the battery terminal cables NOTICE Be sure to disconnect the negative terminal cables first 1518006851 e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter A which can be read to 0 1 volt x If the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 6 V or more Terminal Voltage V A Battery Charge Rate 96 B Refresh charge is required C Note D Good E Brake Light Switch Inspection e Check the operation of the brake light switch by depress ing the brake pedal The brake light should go on after 10 mm 0 39 in of pedal travel A x If it does not adjust the brake light switch A up or down To change
173. ade Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Transmission Gear Ratio Forward High Low Reverse Low Final Drive System Type Reduction Ratio Overall Drive Ratio Forward High Low Reverse Low Front Final Gear Case Oil Type Viscosity Capacity Transmission Oil Type Viscosity Capacity Right to left 1 2 3 Right to left 1 2 3 10 BTDC 45 ABDC 235 45 BBDC 10 ATDC 235 Forced lubrication wet sump API CF or CF 4 SAE 10W 40 3 3 L 3 5 US qt Belt drive torque converter 3 7 0 98 1 821 51 28 3 750 51 28 x 25 20 x 28 17 4 220 41 20 x 25 20 x 28 17 Gear 4WD 2WD 5 429 76 14 9 690 19 950 22 454 Hypoid gear oil for LSD Limited Slip Differential gears SAE 140 GL 5 or SAE 90 GL 6 0 4 L 0 4 US qt Hypoid gear oil SAE 90 above 5 41 SAE 80 below 5 C 41 F 2 5 L 2 6 US qt 1 10 GENERAL INFORMATION General Specifications tems 5009 Frame Type Steel tube Ladder Caster Rake Angle 1 9 0 8 Trail 35 mm 1 4 in Tire Front and Rear 23 x 11 00 10 Tubeless Rim Size Front and Rear 10 x 8 5 AT Steering Type Rack and pinion Electric power steering Suspension Front Type MacPherson strut Wheel Travel 100 mm 3 94 in Rear Type De Dion axle Wheel Travel 70 mm 2 76 in Brake Type Front and Rear Drum Hydraulic Parking Brake Type Drum Mechanical
174. al Upper Wall of Fuel Tank Clamp Output or Return Hoses Air Vent Hose Check Valve Joint To Clamp on Center Bar To Hole in Floor Board From Fuel Tank To Injection Pump From Injection Pump To Fuel Tank Harness and Leads Brake Pipe All Cables Position the tabs of clamps facing toward backside of vehicle Section A A Pass the fuel hose through clamp APPENDIX 18 25 18 26 APPENDIX Cable Wire and Hose Routing KAF950GD 5 qu Si af 1 cu 2 Te 1 MS b m DTP T ZE LLLA Hi 2 2 Qo 2 Ur 1 E 2 up L MN mma Umen CLER te N 0 lli LII LI X 10 eE am HH Ma L puis I HIR CS 119010 e 8 9 1808320814 Cable Wire and Hose Routing 5 Fuel Return Hose Fuel Output Hose Fuel Filter Fuel Pipes Fuel Tank Fitting Seal Upper Wall of Fuel Tank Clamp Output or Return Hoses Air Vent Hose Check Valve
175. al retainer and crankshaft end e Apply liquid gasket A to the mating surface as shown in the figure Sealant Three Bond 1207F When the starter motor install refer to the Starter Motor Installation in the Electrical System chapter e Install the end plate e Tighten Torque End Plate Bolts 39 4 0 kgf m 29 ft Ib 9 26 CRANKSHAFT CRANKCASE End Plate e Apply liquid gasket A to the mating surface as shown in the figure Sealant Three Bond 1207F e Install the flywheel A and coupling e Apply a non permanent locking agent to the threads of the flywheel mounting bolts e Using the flywheel holder B hold the flywheel Special Tool Flywheel Holder 57001 1438 e Tighten the flywheel mounting bolts following the tighten ing sequence as shown in the figure Torque Flywheel Mounting Bolts First 32 3 3 kgf m 24 ft lb Final 44 4 5 32 ft lb e Install the removed parts see appropriate chapters CRANKSHAFT CRANKCASE 9 27 Seal Retainer Oil Seal Replacement e Remove Oil Seal Retainer A see Crankshaft Removal Oil Seal B e Replace the oil seal with new one e Apply engine oil to the outside of the oil seal e Press in a new oil seal so that the seal surface is flush with the end of the hole Special Tool Retainer Oil Seal Driver A 57001 1437 OApply high temperature grease to the oil seal lips 9 28 CRANKSHAFT CRANKCASE Pistons and Crankca
176. al Play Adjustment e ilt up the cargo bed e oosen the adjuster mounting nuts A at the engine end of the cable e Slide the adjuster B until the proper amount of throttle pedal play is obtained e Tighten the adjuster mounting nuts securely e Start the engine e With the transmission in neutral operate the throttle pedal a few times to make sure that the idle speed does not change x If the idle speed does change the throttle cable may be improperly adjusted incorrectly routed or it may be dam aged e Correct any of these conditions before operation A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions NOTE the throttle pedal play can not be adjusted by using the adjuster at the engine end of the cable use the ca ble adjuster A at the throttle pedal Do not forget to securely tighten the adjuster mounting nuts PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Idle Speed Inspection e Start the engine and warm it up thoroughly e ilt up the cargo bed e Check the idle speed with a suitable tachometer A Tachometer Adapter B Idle Speed Standard 850 950 r min rpm x If the idle speed is out of the specified range adjust it Idle Speed Adjustment e Start the engine and warm it up thoroughly e Loosen the locknu
177. al joint clamp bolt A x If the clamp becomes hard to turn search the posi tion that it can be easily turned while turning the steering wheel slowly e Pull out the rubber boot B upward temporary 15 52 STEERING EPS Electric Power Steering System e Move the steering gear assembly and pull off the shaft A from the lower universal joint B OLower the steering gear assembly and then pull it for ward e Remove Rubber Boot C Universal Joint Clamp Bolt D Lower Universal Joint e Remove Steering Shaft see Steering Wheel and Steering Shaft Removal Universal Joint Clamp Bolt A Upper Universal Joint B e Disconnect EPS Motor Connector C Torque Sensor Connector D E KAF950G9 GC HA F KAF950GD e Remove Cotter Pin A Pin B Push Rod C Spring D e Remove the EPS unit mounting bolts A EPS Electric Power Steering System e Remove the EPS unit A downward while pushing down the brake pedal B Olnsert the lower shaft to the hole of the under cover avoid the upper shaft from the frame NOTICE The EPS unit A has been adjusted and set with precision at the factory Do not try to disassemble and repair the EPS unit B KAF950G9 GC HA C KAF950GD EPS Unit Installation e Check that the rubber dampers A and upper and lower collars B are in place on the frame x If the rubber dampers are damaged or deteriorated re place them OWhen installing t
178. ank Overflow Hose B Radiator Overflow Hose C Coolant Reserve Tank Coolant Reserve Tank Installation e Installation is the reverse of removal note the following Olnsert the projection A of the coolant reserve tank into the grommet B on the font cargo compartment ORun the hoses according to the Cable Wire and Hose Routing section in the Appendix chapter OFill the coolant reserve tank with coolant see Coolant Change in the Periodic Maintenance chapter 4 8 COOLING SYSTEM Water Pump Water Pump Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the fan belt cover see Cooling Fan Belt Inspec tion in the Periodic Maintenance chapter e oosen the cooling fan belt see Cooling Fan Belt Inspec tion in the Periodic Maintenance chapter e Remove Fan Mounting Bolts A Spacer B Water Pump Pulley C Fan Belt D e Remove the bracket bolt A and move the fan belt ad justing bracket B forward e Remove Water Pump Hose A Coolant Temperature Switch Lead Connector B Water Pump Mounting Nuts C Water Pump Mounting Bolts D Water Pump E and Bracket F Water Pump Installation e Replace the water pump gasket with a new one e Install the water pump Torque Water Pump Mounting Bolts and Nuts 20 N m 2 0 kgf m 15 ft Ib e Tighten Torque Alternator Adjusting Bracket Bolts 20 N m 2 0 kgf m 15 ft Ib e Adjust the fan belt deflection see Cooling Fa
179. ap ter WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions Throttle Cable Lubrication Whenever the throttle cable is removed lubricate the ca ble as follows e Apply a thin coating of grease to the cable upper and lower ends Lubricate the cable with a penetrating rust inhibitor through a pressure cable luber Throttle Cable Inspection e With the throttle cable disconnected at both ends the ca ble should move freely A within the cable housing x If the cable does not move freely after lubricating if the cable is frayed B or if the housing is kinked C replace the cable FUEL SYSTEM 3 11 6604011451 0004020152 3 12 FUEL SYSTEM Fuel Injection Nozzle Fuel Injection Nozzle Removal e ilt up the cargo bed e Remove Fuel Injection Pipes see Fuel Injection Pipe Removal Fuel Return Hose A Linkage Pipe Nuts B Linkage Pipe C e Remove Washer A Fuel Injection Nozzle B and Gasket NOTICE Handle the fuel injection nozzles with extreme care Do not drop the nozzles Fuel Injection Nozzle Installation e Replace the gasket A with a new one e Install the fuel injection nozzle B Torque Fuel Injection Nozzles 59 N m 6 0 kgf m 44 ft Ib e Replace the washer C with a new one e Install Linkage Pipe D Linkage
180. ar axle B and pull it out from the inside FINAL DRIVE 12 35 Drive Shaft and Axles e Remove Drive Shaft Cap Bolts A Drive Shaft B and Cap C OSet the differential shift lever into the UN LOCK position Rear Drive Shaft and Axle Installation e Wipe the old grease off the splines A of the drive shafts axles and cap oil seals and grease them e Inspect the drive shafts and axles see Drive Shaft and Axle Inspection e Align the yoke angles of the drive shaft and axle e Replace the drive shaft cap gasket with a new one x If the dust boot was removed install it on the axle so that the small hole A in the boot is toward the axle side e Adjust the transmission oil see Transmission Oil Change in the Periodic Maintenance chapter P Drive Shaft and Axle Inspection e Visually inspect the splines of the drive shaft and axle x If they are twisted badly worn or chipped replace the drive shaft and or axle with a new one e Check that the universal joint and or ball joint works smoothly without rattling or sticking x If it does not the bearings of the joint are damaged Re place the drive shaft and or axle with a new one 12 36 FINAL DRIVE Drive Shaft and Axles Dust Boot Inspection e Visually inspect the boots A in accordance with the Peri odic Maintenance Chart or if the drive shafts or axles are noisy during operation xIf the dust boot is torn worn deteriorated or leaks grease
181. ar oil Viscosity SAE 90 above 5 C 41 F or SAE 80 below 5 C 41 F Capacity 2 5 L 2 6 US qt Oil Level Between H and L level lines on dipstick PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Wheels Tires Wheels Nuts Tightness Inspection e Check the tightness of all the wheel nuts xlIf there are loose nut first loosen by 1 2 turn then re torque them to the specified torque Torque Wheel Nuts 137 14 0 kgfm 101 ft Ib OTighten the wheel nuts 1 4 in a criss cross pattern Tire Wear Inspection e Examine the tire for damage and wear x If the tire is cut or cracked replace it OLumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement ORemove any foreign objects from the tread After re moval check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places x If any of the measurements is less than the service limit replace the tire Tire Tread Depth Standard 13 2 mm 0 52 in Service Limit 3 mm 0 12 in Standard Tire Front and Rear 23 x 11 00 10 DUNLOP 869 Tubeless Final Drive Front Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Park the vehicle so that it is level both side to side a
182. are parallel with the rim flanges B x If the rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire e After the beads are properly seated check for air leaks OApply a soap and water solution around the tire bead and check for bubbles e Check the tire pressure using an air pressure gauge Tire Air Pressure when Cold Front 97 kPa 1 0 kgf cm 14 psi Rear 167 kPa 1 7 kgf cm 24 psi e Install the wheel see Wheel Installation e Wipe off the soap and water solution or water on the tire and dry the tire before operation A WARNING Water or soap solution on the tire bead can cause tire separation and an accident resulting in serious injury or death Do not operate the vehicle until any water or soap solution applied to the bead has com pletely dried Tire Inspection e Refer to the Tire Wear Inspection in the Periodic Mainte nance chapter IK06002B 5 FINAL DRIVE 12 1 Final Drive Table of Contents Exploded 12 2 Seclcalons ccce arbi ite ae 12 6 SDeclal 12 7 Front Final Gear 12 8 Front Final Gear Case Oil Level 5 e PT PS 12 8 Front Final Gear Case Oil 12 8 Front Final Gear Case Removal 12 9 Front Final Gear Case Installation 12 9 Front Final Gear Case Disassembly
183. aring Housing Tapered Roller Bearing affects preload only Oil Seal Collar affects preload only Pnion Gear Slotted Nut affects preload only 1104061885 C FINAL DRIVE 12 17 Front Final Gear Case x If the preload is out of the specified range replace the collar and or shim s OTo increase preload decrease the size of the shim s or collar To decrease preload increase the size of the shim s or collar OChange the thickness a little at a time e Recheck the bearing preload and readjust as necessary e Measure the bearing preload using a spring scale Using Spring Scale Pinion Gear Bearing Preload 1 5 3 0 0 15 0 31 kgf 0 34 0 67 Ib OHook the spring scale A on the handle at a point 200 mm 7 87 in B apart from the center of the gear shaft Hold the bearing housing in a vise so that the gear shaft is vertical OApply force to the handle horizontally and at a right angle to it Special Tool Pinion Gear Holder C 57001 1281 e Measure the bearing preload using a torque wrench A Using Torque Wrench Pinion Gear Bearing Preload Torque 0 3 0 6 N m 0 03 0 06 kgf m 2 6 5 2 in Ib Special Tool Pinion Gear Holder B 57001 1281 Backlash Adjustment e Check and adjust the gear backlash when any of the backlash related parts are replaced with new ones e Clean any dirt and oil off the bevel gear teeth e Assemble the front final gear case see Front Final Gear Case Assembly Do not
184. arter System e Remove End Cover Screws A and O rings End Cover B e Remove Armature A Positive Brushes B Brush Plate C e Remove Drive End Cover Screws A Drive End Cover B e Remove Starter Clutch A Idle Gear B Steel Ball C e Remove Retainer A Rollers B ELECTRICAL SYSTEM 17 41 19118045 F 10118047 17 42 ELECTRICAL SYSTEM Electric Starter System e Remove the return spring Starter Motor Assembly e Apply grease to the following parts Retainer and Rollers Starter Clutch Steel Ball Return Spring Armature Bearing Grease Denso No 50 Grease or Equivalent Esso Beacon 325 e Install the retainer A and rollers B on the drive end cover shaft C OFace the opening side D of the retainer to the magnetic switch assy e Install Starter Clutch A Idle Gear B 10118051 P e Install Steel Ball Return Spring Drive End Cover and Screws Electric Starter System e Install the positive brushes on the brush plate B with needle nose pliers OPull the springs C and brushes and hold the brushes with the springs e Install the armature e Install End Cover A End Cover Screws B and O rings e Tighten Torque Starter Motor End Cover Screws 1 5 N m 0 15 kgf m 13 in Ib e Install the yoke A on the magnetic switch B e Tighten Torque Starter Motor Through Bolts 9 3 0 95 kgf m 82 in Ib e Install the field coil
185. becomes hard and apply the brake pedal and hold it 2 Quickly open and close the bleed valve while holding the brake pedal applied 3 Release the brake pedal e Tighten Torque Bleed Valves 5 4 N m 0 55 kgf m 48 in Ib e Repeat the previous step for each wheel e When air bleeding is finished add fluid up to the upper level in the reservoir e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings e Install the removed parts see appropriate chapters Torque Master Cylinder Reservoir Cap 3 4 0 35 kgf m 30 in Ib BRAKES 13 9 13 10 BRAKES Brake Pedal and Master Cylinder Brake Pedal Play Inspection e Refer to the Brake Pedal Play Inspection in the Periodic Maintenance chapter Master Cylinder Removal e Remove Front Cargo Compartment see Front Cargo Compart ment Removal in the Frame chapter Brake Hose Banjo Bolts A Brake Pipe Nipple B Unscrew e Immediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove Master Cylinder Mounting Bolts C Master Cylinder D Master Cylinder Installation e Use a new flat washer on each side of the brake hose fitting e Apply brake fluid to the threads of the brake pipe nipple e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Nipples 18 1 8 kgf
186. ble C 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Starter Motor Lead Connector A Starter Motor Cable B Engine Ground Cable C e Remove the engine mounting bolts A and washers e Remove the engine A e Remove Engine Bracket Bolts A Both Sides Engine Bracket B ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation Engine Installation e Install the engine on the bracket e Apply a non permanent locking agent to the threads of the engine bracket bolts and tighten them e Adjust the engine mounting position for alignment of the torque converter OMount the engine and install the engine mounting bolts loosely Olnstall the assembly jig A onto the transmission driven shaft and crankshaft as shown in the figure Special Tool Assembly Jig 57001 1566 OScrew in the bolt B until the assembly jig is fitted to the transmission driven shaft The length C between the jig and the end of coupling is 5 mm 0 20 in OTighten Torque Engine Mounting Bolts 44 N m 4 5 kgf m 32 ft Ib ORemove the assembly jig e Install the removed parts see appropriate chapters e Tighten Torque Stay Rod Rear Nut 88 N m 9 0 kgfm 65 ft Ib e Adjust Engine Oil see Engine Oil and or Oil Filter Change in the Periodic Maintenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter i cen gt 0
187. c tion feels too soft or too stiff adjust itin accordance with the following table Spring Action Force Weak ooft T n n nun NA the rear wheel see Wheel Removal in the Wheels Tires chapter e urn the adjusting sleeve on each rear shock absorber to the desired position with the wrench A Special Tool Steering Stem Nut Wrench 57001 1100 OBoth adjusting sleeves left and right must be turned to the same relative position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Be sure the adjusters are set equally Rear Shock Absorber Removal e Remove Rear Wheel see Wheel Removal in the Wheels Tires chapter Rear Shock Absorber Mounting Bolts and Nuts A while moving the frame up or down with a jack Rear Shock Absorber B Rear Shock Absorber Installation e Install the rear wheel temporarily and ground it to load the Suspension e Replace the rear shock absorber mounting nuts with new ones e Tighten Torque Rear Shock Absorber Mounting Nuts 59 6 0 kgf m 44 ft Ib SUSPENSION 14 9 14 10 SUSPENSION Struts and Rear Shock Absorbers Shock Absorber Inspection e Visually inspect the shock absorber for breaks or distor tion x If the shock absorber is damaged in any way replace it e Check for oil leakage at the shock absorber damper unit If oil leakage is noted the shock absorber should be re placed t
188. cable C has no slack while holding the shift lever in the 4WD position e Tighten the lower adjuster nut D securely 2WD 4WD Shift Cable Lubrication Whenever the shift cable is removed lubricate the cable as follows e Apply a thin coating of grease to the cable ends Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber TRANSMISSION 10 25 6604011451 10 26 TRANSMISSION 2WD AWD Shift Mechanism 2WD 4WD Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely A within the cable housing the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable 2WD 4WD Shift Mechanism Removal e Remove Hi Low Gear Case see Hi Low Gear and Shift Mecha nism Removal Shift Shaft Stop Bolt A and Washer e Remove Shift Shaft Lever Mounting Nut A Shift Shaft Lever B Spring C e Remove O ring A Shift Shaft B e Remove Shifter A Circlip B Speedometer Gear C Collar Special Tool Outside Circlip Pliers 57001 144 2WD 4WD Shift Mechanism Installation e Apply transmission oil to the following parts Speedometer Gear Shifter 6004040231 TRANSMISSION 10 27 2WD AWD Shift Mechanism e Replace the circlip that was removed with a new one NOTE OAlways install the circlip A so that the opening B is aligned with a spline groove To install a circlip without damage f
189. cable and tighten nut securely Carbon Brush Inspection e Measure the carbon brush length A x If the brush length is less than the service limit replace the brush assembly Carbon Brush Length Standard 15 5 mm 0 61 in Service Limit 11 0 mm 0 43 in Yoke Inspection e Measure the resistance between the carbon brush and the wire terminal Special Tool Hand Tester 57001 1394 x If there is not close to 0 the field coils have an open Replace the yoke e Measure the resistance between the carbon brush and the yoke body B x If there is any reading the yoke has a short Replace the yoke ELECTRICAL SYSTEM 17 43 10118052 P 19118054 F 17 44 ELECTRICAL SYSTEM Electric Starter System Brush Plate Inspection e Measure the resistance between the carbon brush and the brush plate A Special Tool Hand Tester 57001 1394 lf there is not close to 0 Q the brush plate has an open Replace the brush plate e Measure the resistance between the brush plate and the brush holder B x If there is any reading the brush plate has a short Re place the brush plate Commutator Cleaning Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commwutator Diameter Standar
190. can be explo sive under certain conditions creating the potential for serious burns Make sure the area is well venti lated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the main switch off Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTICE Never drop the fuel level gauge especially on a hard surface Such a shock to the fuel level gauge can damage it e Tilt up the seat e Draw the fuel out from the fuel tank with a commercially available electric pump FUEL SYSTEM 3 37 HC08010731 HC08004BS31 3 38 FUEL SYSTEM Fuel Tank e Remove Fuel Level Gauge Lead Connector A Fuel Level Gauge Mounting Bolts B Plate C Fuel Level Gauge D e Discard the O ring A Fuel Level Gauge Installation KAF950GD e Remove dirt or dust from the fuel level gauge A by lightly applying compressed air e Replace the O ring with a new one and install it in the groove on the fuel tank e Install the fuel level gauge A and plate B so that the projections C fit into the recesses e lighten Torque Fuel Level Gauge Mounting Bolts 4 0 0 41 kgf m 35 in Ib COOLING SYSTEM 4 1 Cooling System Table of Contents E XDIOGEG VIEW M
191. cap counterclockwise to the first step OThen push and turn it further in the same direction and remove the cap e Tighten the drain plugs e Install the reserve tank hose and reserve tank e Tighten Torque Coolant Reserve Tank Bolt 4 4 0 45 kgf m 39 in Ib e Lift the front wheels 20 30 cm 7 9 11 8 in from the ground so that the radiator cap is the highest port of the system e Pour the coolant slowly into the radiator cap fitting NOTE OPour in the coolant slowly so that the air in the engine and radiator can escape 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures M 5524 7 A KX KO 1 ERN ALY 18060068882 Front A Radiator Cap C Air Bleeder Bolt B Reserve Tank Cap D NOTICE Soft or distilled water must be used with antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages considerably reducing the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 31 F Total Amount 4 4L 4 7 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions e When the coolant begins to flow out the air bleeder bolt holes tighten the air bleeder bolt e Fill the cooling system up to the filler neck A in the radi ator cap fitting with coolant
192. caps Crankshaft Installation e Install the upper main bearing inserts in the crankcase NOTE OUpper main bearing inserts have an oil groove A and oil hole B OBe sure the bearing inserts are seated in the saddles and the tangs in the bearing inserts are aligned with the notches in the saddles 9 20 CRANKSHAFT CRANKCASE Crankshaft and Connecting Rods e Install the lower main bearing inserts A in the bearing caps B OBe sure the bearing inserts are seated in the bearing caps and the tangs C in the bearing inserts are aligned with the notches D in the bearing caps e Apply engine oil to the main bearing inserts e nstall the thrust washers A at 3 main bearing with grooves B facing out e Install the crankshaft with the gear facing the right side timing gears side OTake care not to damage the journals or bearing inserts e Apply engine oil to the crankshaft main journals e Install the main bearing caps in their respective positions with the arrows A facing the right side timing gear side e Tighten the cap bolts following tightening sequence 1 4 Torque Crankshaft Main Bearing Cap Bolts 59 N m 6 0 kgf m 44 ft Ib OAfter tightening the cap bolts make sure the crankshaft rotates freely e Install New Oil Seal Retainer Gasket A Dowel Pins B Oil Seal Retainer e Tighten Torque Oil Seal Retainer Bolts 5 4 N m 0 55 kgf m 48 Connecting Rod Big End Side
193. ce 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 to the inlet manifold Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned 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 injection pump and injection timing characteristics The fuel system has been calibrated to provide lean air fuel mixture characteristics with a suitable air cleaner and exhaust system A maintenance free injection system provides the most appropriate injection timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 The following acts and the causing thereof are prohibited 3 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 und
194. conditions in your riding area lt SAE 10 50 10W 50 emen m m pees 1509000851 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Removal e ilt up the cargo bed e Remove the oil filter A from under the vehicle OWhen unscrewing the oil filter cover the filter bottom with a clean cloth so as not to spill the engine oil out of the filter Any spilled oil should be wiped up completely Oil Filter Installation e Apply engine oil to the oil filter gasket e Install a new filter OScrew the filter in until the gasket touches the engine then turn it 1 turn e Add the engine oil see Engine Oil and or Oil Filter Change e Thoroughly warm up the engine and check for oil leakage and the oil level If necessary add more engine oil Transmission Transmission Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Place an oil pan beneath the transmission case e Remove the transmission oil drain plug A and let the oil drain completely e Replace the gasket with a new one e After the oil has completely drained out install the drain plug with the gasket Torque Transmission Oil Drain Plug 15 N m 1 5 kgfm 11 ft Ib e Fill the transmission case with a good quality oil as spec ified in the table e Check the oil level Transmission Oil Type Hypoid ge
195. crews e Tighten Torque Wear Shoe Mounting Screws 1 1 0 11 kgf m dk 522 10 in Ib e Hold the fixed sheave with the drive amp driven pulley holder and driven pulley holder in a vise Special Tools Drive amp Driven Pulley Holder 57001 1412 Driven Pulley Holder 57001 1465 e Install the spacer s A on the fixed sheave B hy n ay e Install Movable Sheave A Spring B Olnsert the spring end into the hole C on the movable sheave e Install the ramp A on the fixed sheave shaft e Insert the spring end B into the hole 1 on the ramp e Put the washer C and circlip D on the ramp OThe washer shall be installed so that the recess of it faces outward e Install the spring holder A e Align the flat portions B of spline of the fixed sheave and ramp and push down the ramp halfway by tightening the flange nut C e Hold the movable sheave D by turning it counterclock wise 120 and tighten the flange nut until the bottom of ramp hits the movable sheave e Install the washer and new circlip Special Tool Outside Circlip Pliers 57001 144 e Release the movable sheave slowly until it stops naturally 6 28 CONVERTER SYSTEM Driven Pulley Driven Pulley Installation e Clean the transmission driven shaft A and apply molyb denum disulfide grease width the specified range on it 20 25 mm 0 79 0 98 in B 5 10 mm 0 20 0 39 in C OApply molybdenu
196. ction Pump Drive Gear see Timing Gear Case Removal in Crankshaft Crankcase chapter Fuel Injection Pipes see Fuel Injection Pipe Removal Fuel Return Hose A Fuel Injection Pump Bracket Bolts B Fuel Injection Pump Bracket C e Remove Fuel Injection Pump Mounting Nuts A Fuel Injection Pump B Fuel Injection Pump Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Install the fuel injection pump temporary OAlign the timing marks A on the injection pump and tim ing gear case OTighten the mounting nuts with fingers FUEL SYSTEM 3 17 3 18 FUEL SYSTEM Fuel Injection Pump e Install Fuel Injection Pump Drive Gear Timing Gear Case Cover and Crankshaft Pulley see Timing Gear Case Installation in the Crankshaft Crankcase chapter e Adjust the fuel injection pump timing see Fuel Injection Pump Timing Inspection e Tighten Torque Fuel Injection Pipe Mounting Nuts 25 2 5 kgf m 18 ft lb Fuel Injection Pipe Clamp Bolts 7 4 N m 0 75 kgf m 65 in Ib e Adjust Maximum Engine Speed New Injection Pump see Maximum Engine Speed Adjustment Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Fuel Injection Pump Timing Inspection e Remove Fan Belt Cover see Cooling Fan Belt Inspection in the Periodic Maintenance chapter Fuel Injection Pipes see Fuel Injection Pipe Removal Cylinder Head Cover see Rocker Arm Components Re moval in t
197. d 17 50 Fuel Cut Solenoid Inspection 17 50 25 17 51 Radiator Fan Circuit Inspection 17 51 Radiator Fan Motor Inspection 17 51 Radiator Fan Breaker Inspection 17 51 Radiator Fan Relay Inspection 17 52 Meter 17 54 Speedometer Removal 17 54 Speedometer Installation 17 54 Fuel Gauge Hour Meter Removal ISAT 95009 D 17 55 Fuel Gauge Hour Meter Installation KAF950GD 17 55 Fuel Gauge LED Inspection 17 55 Fuel Level Gauge Inspection KAP 950 D 17 56 Lighting System 17 57 Headlight Beam Adjustment 17 57 Headlight Bulb Replacement 17 57 Tail Brake Light Replacement 17 57 Light Switch Bulb Replacement 17 58 Indicator Light Bulb Replacement 17 59 Speedometer Illumination Bulb Replacement 17 59 Headlight Remowval 17 60 Headlight Installation 17 60 Reverse Light Switch Installation EUR M del 17 60 Switches and Sensors 17 62 Brake Light Switch Inspection 17 62 Radiator Fan Switch Inspection 17 62 Coolant Temperature Switch Inspection 17 63 Switch Inspection 17 64 Speed Sensor Removal 17
198. d 30 mm 1 18 in Service Limit 29 mm 1 14 in Armature Inspection e Using the x 1 O range of the hand tester measure the resistance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between any two segments a winding is open Replace the starter motor e Using the highest range of the hand tester measure the resistance between the segments and the shaft B x If there is any reading at all the armature has a short Replace the starter motor NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one 10118055 P GP11061031 GP11060831 Electric Starter System Pinion Gear Inspection e urn the pinion gear by hand It should turn clockwise freely A but should not turn freely counterclockwise B x If the pinion gear does not operate as it should or if there is any worn or damaged part replace it Starter Switch Inspection e Connect a 12 V battery to the starter switch A as shown in the figure OConnect the battery negative cable B first and then the positive lead to the terminal in the connector C x If the switch does not wor
199. d EPS unit trouble EPS ECU trouble Noise when turning Damaged side gear or pinion front final gear case Worn clutch friction plate front final gear case Worn clutch spring front final gear case ESP unit mount loose Steering wheel shakes or excessively vibrates Tire s worn Suspension arm bushing worn Tie rod joint worn Wheel rim warped Axle shaft bearing worn Steering wheel mount loose Steering bolt or nut loose Steering wheel pulls to one side Frame bent Wheel misalignment Suspension arm bent or twisted Steering shaft bent Steering gear assembly damaged Front or rear tire air pressure unbalanced Shock absorber unbalanced not properly 18 34 APPENDIX Troubleshooting Guide Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber damaged Too soft Tire air pressure too low Shock absorber oil leaking Shock absorber spring weak Brake Doesn t Hold Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master or wheel cylinder scratched inside Brake not properly adjusted Linings overworn or worn unevenly Drum worn unevenly or scored Oil grease on lining and drum Dirt water between lining and drum Overheated brakes Battery Trouble Battery discharged Battery faulty Battery cable making poor contact Load excessive e g bulb of excessive wattage Main switch trouble Alternator trouble Wiring faulty Batte
200. d adjusters C near the rear wheels Be sure to adjust both the left and right cables evenly and then securely tighten the adjuster mounting nuts D 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Check steering wheel free play A OSet the front wheels straight ahead Gently turn B the steering wheel left and right The steering wheel free play is the amount of travel in the steering wheel before the front wheels begin to turn Steering Wheel Free Play Standard 0 20 mm 0 0 79 in If steering wheel free play is not correct inspect the fol lowing Steering Wheel Mounting Nut see Steering Wheel Cen tering in the Steering chapter Universal Joint Clamp Bolts see Exploded View in the Steering chapter EPS Unit Mounting Bolts see EPS Unit Installation in the Steering chapter Steering Gear Assembly Bracket Bolts see Steering Gear Assembly Installation in the Steering chapter Steering Gear Assembly Mounting Rubber Dampers Tie Rod End Nuts see Steering Gear Assembly Instal lation in the Steering chapter Steering Gear Preload Adjustment see Steering Gear Preload Adjustment in the Steering chapter x If the inspections above are good but the free play is out of the specified the steering gear assembly is damaged and should be replaced as a unit Steering Joint Dust Boot Inspection e Visually inspect the dust boots A at both the ends of the steering gear assembly
201. d the position will be secured e Apply soapsuds to inside area of the new grease seal e Put the brake panel on a suitable flat plate A so that the bleed valve fitting B boss C and parking brake lever linkage D rear only are not contact to the plate e Putthe guide E in the panel so that the UP mark F faces upward Special Tool Grease Seal Driver Set 57001 1629 e Put the grease seal G on the brake panel evenly e Put the grease seal driver A on the grease seal evenly Special Tool Grease Seal Driver Set 57001 1629 e Putthe compressor B to center on the grease seal driver Special Tool Clutch Spring Compressor 57001 1162 e Using a press install the grease seal e Pack lithium grease NLGI Grade No 2 to the grease seal lips see Brake Drum Installation Parking Brake Lever and Cables Parking Brake Lever Travel Adjustment e Refer to the Parking Brake Lever Inspection in the Peri odic Maintenance chapter Parking Brake Cable Lubrication Inspection e Refer to the General Lubrication in the Periodic Mainte nance chapter BRAKES 13 23 SUSPENSION 14 1 Suspension Table of Contents 14 2 DDC CINCAUONS anew 14 4 REUS UU OTT 14 5 Strut and Rear onockZDSOIDGO S T 14 6 Strut Front Shock Absorber 14 6 S
202. d all the piston rings e With new piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Top Second and Oil Ring Service Limit less than 0 12 mm 0 0047 in x If the piston ring groove clearance is greater than the ser vice limit replace the piston 1106005881 CRANKSHAFT CRANKCASE 9 33 Pistons and Crankcase Piston Ring End Gap e Clean the carbon from the ends of the rings e Place the piston ring inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap between the ends ofthe ring with a thick ness gauge Piston Ring End Gap Top Second and Oil Ring Service Limit 0 70 mm 0 0276 in x If the gap is wider than the service limit the ring is over worn and must be replaced NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring Thickness e Measure the piston ring thickness OUse micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 1 445 1 465 mm 0 0569 0 0577 in Second 1 470 1 490 mm 0 0579 0 0587 in 2 970 2 990 mm 0 1169 0 1177 Piston and Piston Pin Wear e Measure the inside diam
203. d 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 2008 Kawasaki Heavy Industries Ltd 5th Edition 1 May 18 2012 LIST OF ABBREVIATIONS ampere s pounds s after bottom dead center meter s alternating current minute s after top dead center newton s before bottom dead center pascal s bottom dead center horsepower before top dead center pound s square inch degree s Celsius revolution direct current revolution s per minute farad s top dead center degree s Fahrenheit total indicator reading foot feet volt s gram s watt s hour s ohm s liter s COUNTRY AND AREA CODES EUR Europe US United States CA Canada EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in complian
204. d hollow screw in are assembled properly Good Check to see if fuel leakage exists Good Check to see if maximum engine speed under no load state conforms to specification Good Check to see if injection timing is proper Good Check to see if fuel injection nozzle is functioning properly Good Malfunctioning injection pump No good No good No good No good No good No good No good FUEL SYSTEM 3 25 Replace fuel filter Adjust throttle cable Correct assembly of screws Replace or retighten within specified value Adjustment of maximum speed set screw Adjust injection timing Defective fuel injection nozzle 10120038 3 26 FUEL SYSTEM Fuel Injection Pump Troubleshooting Engine will not stop even after main switch is turned OFF Check to see if fuel cut solenoid functioning Engine can stop properly Engine still can not stop Defective fuel cut solenoid valve foreign matter lodged Poor sealing surface of injection pump distributor head Crankcase may be overfilled with oil Excessive hydrocarbon vapors near the vehicle as when refueling Replace main switch Abnormal Noise Bad Check to see if water temperature rises sufficiently Good Bad Check to see if injection timing is proper Good Bad Check to see if fuel injection nozzle is functioning properly Good Malfunctioning injection pump Defective thermostat Adjust injection timing
205. der head Valve Guide Inside Diameter Standard 6 000 6 015 mm 0 2362 0 2368 in Service Limit 6 036 mm 0 2376 in OMeasure the outside diameter of the valve guide re moved x If the diameter is 11 05 mm 0 4350 in replace it with a replacement valve guide x If the diameter is 11 08 mm 0 4362 in it is a replace ment valve guide Replace the cylinder head Valve Guide Outside Diameter Standard Valve Guide 11 05 mm 0 4350 in Replacement Valve Guide 11 08 mm 0 4362 in ENGINE TOP END 5 21 GF08060331 05005 81 5 22 ENGINE TOP END Valves Measuring Valve Guide Clearance e Subtract the valve stem diameter from the valve guide inside diameter to get the valve valve guide clearance Valve Guide Clearance Standard Inlet 0 055 0 070 mm 0 0022 0 0028 in Exhaust 0 035 0 050 mm 0 0014 0 0020 in Service Limit Inlet 0 090 mm 0 0035 in Exhaust 0 094 mm 0 0037 in Valve Stem Cap Inspection e Visually inspect the valve stem cap A for wear x If the cap is worn replace it EO5006BS1 Exhaust Pipe and Muffler Exhaust Pipe Removal e ilt up the cargo bed e Remove Bolts A and Washers Exhaust Pipe Cover B e Remove the exhaust pipe holder nuts A e Remove Joint Bolts and Nuts A Exhaust Pipe B Muffler Removal e Remove the joint bolts and nuts A e Remove Muffler Mounting Bolts A and washers Muffler B ENGINE TOP END 5 23
206. diagnosis Procedure Service Code Reading Service Code Erasing STEERING 15 1 Steering Table of Contents 15 2 15 4 15 5 15 6 15 6 15 6 15 6 15 7 Service Code Erasing PProcedul ess suse nto Das 15 35 EPS Neutral Position Registration 15 37 Power Supply Voltage Abnormal Service Code 11 12 15 40 EPS Neutral Position Unregistration Service Ge 15 40 Current Sensor Inspection Service Code 32 15 40 FET Field Effect Transistor Inspection Service Code 33 15 41 Internal Relay Inspection Service Ode 34 20 15 41 CPU Central Processing Unit Inspection Service Code 35 15 42 Direction Distinction Circuit Inspection Service Code 36 15 42 Boosting Transformer Circuit Inspection Service Code 37 15 42 EPS Torque Sensor Inspection Service Code 51 15 43 EPS Motor Inspection Service Code 15 44 EPS Warning Indicator Light LED Remoxwval 15 45 EPS Warning Indicator Light LED Inspection EPS ECU Removal EPS ECU Installation EPS ECU Power Supply Voltage Inspection EPS Motor Removal EPS Torque Sensor Removal EPS Unit Removal EPS Unit Installation Speed Sensor Removal I
207. disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 12 4 FINAL DRIVE Exploded View FINAL DRIVE 12 5 Exploded View 2 BeelGeaCaseBos 22 22 16 3 Bevel Gear Case Holder nus 25 28 18 S Drive Shat Cap Bos 20 20 15 DivnGeaShatNu 168 Mo 707 Ll Housing Lont 420 S0 Ll 79 Propeller Shaft Bearing Housing Cover Bols 34 035 110 Speed Sensors 090 78i 11 KAF950G9 GC HA 12 EUR Model G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts TO Apply transmission 12 6 FINAL DRIVE Specifications tem Standard Front Final Gear Case Gear Case Oil Type Viscosity Capacity Oil Level LSD Clutch Torque Outside Friction Plate Thickness Inside Friction Plate Thickness Pinion Gear Bearing Preload Pinion Gear Bearing Preload Torque Bevel Gear Backlash Bevel Gear Case Bevel Gear Backlash Hypoid gear oil for LSD Lore Limited Slip Differential gears SAE 140 GL 5 or SAE 90 GL 6 0 4 L 0 4 US qt ss Filler opening level ere e 7 8 13 Nm is 0 8 1 3 kgf m 69 115 in
208. ditions Turn the main switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Tilt up the seat e Pry off the gauge cap A and discard the cap e Check the grooves B in the fuel tank boss x If the grooves are damaged by removing the cap or can not hold the cap nails the fuel tank must be replaced e Pull out the fuel level gauge C Fuel Tank Fuel Level Gauge Installation KAF950G9 GC HA WARNING Fuel is extremely flammable and can be explosive under certain conditions Turn the main switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Install the fuel level gauge so that the 1 2 scale A faces the left B of the vehicle e Push the new gauge cap over the gauge so that the notch C aligns with the 1 2 scale e Check that the gauge cap nails fit securely in the grooves in the fuel tank boss Fuel Level Gauge Check KAF950G9 GC HA e Remove the fuel level gauge from the fuel tank see Fuel Level Gauge Removal e Check that the float moves up and down B smoothly without binding It should go down under its own weight x If the float does not move smoothly or has visual damage replace the gauge Fuel Level Gauge Removal KAF950GD A WARNING Gasoline is extremely flammable and
209. e arrow side A into the ramp weight C using the special tool so that the end of bushing is flush with the shoulder D in the hole Special Tool Bearing Driver Set 57001 1129 IF06041BS1 e Install the fan cover Torque Fan Cover Bolts 8 8 0 90 kgf m 78 in Ib e nstall the torque converter outer cover see Torque Con verter Outer Cover Installation 6 24 CONVERTER SYSTEM Driven Pulley Driven Pulley Removal e Remove Drive Pulley see Drive Pulley Removal Torque Converter Inner Cover see Torque Converter In ner Cover Removal Drive Belt see Drive Belt Removal e Using a flywheel amp pulley holder A remove the driven pulley bolt B and stepped collar Special Tool Flywheel amp Pulley Holder 57001 1605 e Remove the driven pulley Driven Pulley Disassembly e Hold the drive amp driven pulley holder A in a vise Special Tool Drive amp Driven Pulley Holder 57001 1412 e Screw the guide bar B of the driven pulley holder into the holder Special Tool Driven Pulley Holder 57001 1465 e Put the driven pulley C on the guide bar e Tighten the nut D and compress the spring with the spring holder E of the driven pulley holder Special Tool Driven Pulley Holder 57001 1465 e Remove the circlip A with circlip pliers B Special Tool Outside Circlip Pliers 57001 144 e Remove the nut and spring holder C CONVERTER SYSTEM 6 25 Driven Pulley e Remove
210. e checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use one of these for check ing the bevel gears Front Final Gear Case e Assemble the front final gear case see Front Final Gear Case Assembly Do not install the O rings during adjust ment e Turn the pinion gear shaft for one revolution in the drive and reverse coast direction while creating a drag on the ring gear OUse the pinion gear holder A and the left front axle Special Tool Pinion Gear Holder 57001 1281 e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth OThe tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x If the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE Olf the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before chec
211. e fuel injection pump drive gear 9 14 CRANKSHAFT CRANKCASE Timing Gear Case e Visually inspect the oil pump drive gear teeth A for wear and damage x If the teeth are damaged or worn replace the oil pump drive gear CRANKSHAFT CRANKCASE 9 15 Camshaft Camshaft Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Valve Lifters see Valve Lifter Removal in the Engine Top End chapter Oil Pan see Oil Pan and Oil Strainer Removal in the Engine Lubrication System chapter Timing Gear Case Cover see Timing Gear Case Re moval e Temporarily install the flywheel to hold the crankshaft e Using the flywheel holder A angled toward the rear of the engine hold the crankshaft Special Tool Flywheel Holder 57001 1438 e Remove Camshaft Drive Gear Bolt A Camshaft Drive Gear B OMark the positions A of the camshaft drive gear B and idle gear C so that the camshaft drive gear can be in stalled later in the same position ODo not turn the idle gear while the camshaft drive gear is removed 9 16 CRANKSHAFT CRANKCASE Camshaft e Remove Camshaft Retainer Bolts A Camshaft Retainer B Camshaft C OUse care when removing camshaft to prevent damag ing the cam bearings journals and lobes Camshaft Installation e Apply engine oil to all cam parts and journals e Install the cams
212. e pulley one more turn to free the rocker arms e Remove Rocker Arm Components Mounting Nuts A and Wash ers B Rocker Arm Components C Rocker Arm Components Installation e Install the rocker arm components Torque Rocker Arm Components Mounting Nuts 20 N m 2 0 15 ft Ib e Inspect the valve clearance see Valve Clearance Inspec tion in the Periodic Maintenance chapter e Tighten Torque Cylinder Head Cover Nuts 5 4 0 55 kgfm 48 in Ib e Install the breather hose OTwist the breather hose so that the white marks B face upward and the center part is higher than both ends ENGINE TOP END 5 11 Rocker Shaft and Rocker Arm Rocker Arm Components Disassembly e Remove Rocker Arm Components see Rocker Arm Components Removal Circlips A Special Tool Outside Circlip Pliers B 57001 144 e Remove Rocker Arms A Rocker Arm Supports B Washers C Springs D Set Bolt E Rocker Shaft F Rocker Arm Components Assembly e Apply engine oil to the all components e Small grooves next to oil holes A in the rocker shaft B must face down e Install the center rocker arm support C as shown in the figure and tighten the set bolt Left Lower Oil Hole D e Install Rocker Arms A Springs B Rocker Arm Supports C Washers D New Circlips E Special Tool Outside Circlip Pliers 57001 144 Rocker Arm Shaft Wear e Measure the inside diameter A of the rocker arm x
213. e they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims tightly Tire Installation e Inspect the rim e Check the tire for wear and damage e Replace the air valve with a new one NOTICE Replace the air valve whenever the tire is replaced Do not reuse the air valve e Lubricate the tire beads and rim flanges with soap and water solution or water A WARNING Do not use any lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation and a hazardous condition may result e Install the tire on the rim using a suitable commercially available tire changer ubricate the tire beads again and center the tire on the rim e Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 36 psi A WARNING Overinflating a tire can cause it to explode causing serious injury or death Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than maximum pressure IK06001B 5 11 10 WHEELS TIRES Tires e Check to see that the rim lines A on both sides of the tire
214. e tool with a vice if necessary e Be sure the outside diameter of the band A is less than the maximum diameter Maximum Outside Diameter of Band 68 9 mm 2 71 in Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin A the bearing by hand to check its condition x If the bearing B is noisy does not spin smoothly or has any rough spots replace it um i ANNES WANS 1107016881 6J08040831 Drive Shaft and Axles Grease Seal Inspection e Visually inspect the grease seals Replace if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or been oth erwise damage FINAL DRIVE 12 43 BRAKES 13 1 Brakes Table of Contents CMM cuiu 13 2 OE TTE 13 6 SpbeoalloalsS 13 7 Brake C 13 8 Brake 13 9 Brake Fluid
215. ecified torque Torque Universal Joint Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib 1004004851 Steering Wheel and Main Shaft Assembly e Install Horn Switch Contact A Holder B Screws C OPosition the horn switch contact on the projection D e Connect the horn switch lead connector A and clamp the bands B e Mount the steering wheel on the steering shaft temporar e Adjust the following items Steering Wheel Position see Steering Wheel Position Adjustment Steering Wheel Centering see Steering Wheel Center ing e Replace the self locknut with a new one e Tighten Torque Self lock Nut 52 N m 5 3 kgf m 38 ft lb e Install the horn switch A as follows OFit the front stoppers B in the recesses C of the steering wheel OFit the rear stopper A in the recess of the steering wheel and push the rear part until sound click STEERING 15 9 15 10 STEERING Steering Wheel and Main Shaft Assembly e nstall the wheel cap A so that the arrow mark B faces front and the stoppers C fit the recesses D of the horn switch e Be sure to register the EPS neutral position see EPS Neutral Position Registration Steering Wheel and Steering Shaft Removal KAF950GD e Clear the hook portions A from the steering wheel to remove the wheel cover B e Remove the wheel cover e Remove Steering Wheel Mounting Nut A and Washer B Steering Wheel e Remove the washer A
216. ect width A and even all the way around NOTE OThe valve stem and guide must be in good condition or this check will not be valid x If the valve seating pattern is not correct repair the seat e Measure the outside diameter B of the seating pattern on the valve seat x If the outside diameter of the valve seating pattern is too large or too small repair the seat Valve Seating Surface C Too Wide G Valve D Too Narrow H Valve Seat E Uneven I Good F Valve Seating Surface Width Standard 0 8 1 2 mm 0 0315 0 0472 in Valve Seating Surface Outside Diameter Inlet 28 mm 1 1024 in Exhaust 24 5 mm 0 9646 in ENGINE TOP END 5 15 EQ5009B32 5 16 ENGINE TOP END Valves Valve Seat Repair e Follow the manufacturer s instructions for use of valve seat cutters Special Tools Valve Seat Cutter Holder 5 5 57001 1125 Valve Seat Cutter Holder Bar 57001 1128 For Inlet Valve Seat Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 60 530 57001 1123 For Exhaust Valve Seat Valve Seat Cutter 32 528 57001 1119 Valve Seat Cutter 30 530 57001 1120 If the manufacturer s instructions are not available use the following procedure Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia
217. ee Fuse Inspection Oil Pressure Switch Oil Pressure Warning Indicator Light Power Source Wiring and Ground Wiring Refer to the next wiring diagram 15 50 STEERING EPS Electric Power Steering System EPS ECU Power Source Circuit 9 1 EPS 6 Battery 12 V 52 Ah 2 EPS Fuse 40 A 7 Main Fuse A 3 EPS Fuse 7 5 A 8 Fuse Box 2 4 Oil Pressure Warning Indicator Light 9 Oil Pressure Switch 5 Main Switch EPS Motor Removal NOTICE Do not remove the EPS motor A from the EPS unit since it has been adjusted and set with precision at the factory B KAF950G9 GC HA C KAF950GD STEERING 15 51 EPS Electric Power Steering System EPS Torque Sensor Removal NOTICE Do not remove the EPS torque sensor A from the EPS unit since it has been adjusted and set with precision at the factory EPS Unit Removal NOTICE The EPS unit A has been adjusted and set with pre cision at the factory Therefore it should be han dled carefully never struck sharply as with a ham mer or allowed to fall on a hard surface Be careful not to get water or mud on the EPS unit e Remove Radiator see Radiator Removal in the Cooling System chapter Left Radiator Side Cover see Radiator Side Cover Re moval in the Frame chapter Water Hoses A e Remove the steering gear assembly bracket bolts B and brackets C e Remove the mounting bolts A of the water pipe e Remove the univers
218. eering wheel is operated as follows the steering wheel may become heavy Turn the steering wheel fully to both sides continuously for a long time the steering wheel fully and keeps it for a long time In these cases the EPS ECU reduces the current to the EPS motor to protect the EPS motor from overheating Therefore this is not trouble Free the hands from the steering wheel and only have to wait for a while 6 The EPS warning indicator light LED might go off by the following operation Stop the engine and start the engine again If the indicator light LED goes off it is a temporary failure Therefore erase the service code memorized in the EPS ECU with the service code erase mode 10080218 15 30 STEERING EPS Electric Power Steering System Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of condition the rider is dissatisfied with to find out exactly what problem occurs under exactly what conditions by asking the rider know ing this information may help you reproduce the problem in the shop OThe following sample diagnosis sheet will help prevent you from overlooking any keys so always use it Sample Diagnosis Sheet Rider name Year of initial registration Engine No Date problem occurred Weather Registration No license plate No Model Frame Problem frequency Mileage L Steering wheel is heavy L
219. ehicle left side B Steering Gear Assembly Installation e Adjust the following items if necessary Steering Gear Preload see Steering Gear Preload Ad justment Tie Rod Length see Tie Rod Length Adjustment e Clean the tapered portion of the tie rod end joint and the tapered hole of the steering knuckle or the tapers will not fit snugly e Apply grease to the sealing surface A of the tie rod end joint boot Steering Gear Assembly e Install the rubber boot A on the shaft B of the steering gear assembly temporary e Install the shaft of the steering gear assembly to the lower universal joint C e Install the universal joint clamp bolt D while aligning the notch on the shaft of the steering gear assembly with the clamp bolt hole on the lower universal joint and tighten it temporary e Install Rubber Dampers E Brackets F e Apply a non permanent locking agent to the steering gear assembly bracket bolts G and tighten them evenly Torque Steering Gear Assembly Bracket Bolts 52 N m 5 3 kgf m 38 e Tighten the universal joint clamp bolt to the specified torque Torque Universal Joint Clamp Bolt 20 N m 2 0 kgf m 15 ft Ib H KAF950G9 GC HA KAF950GD e Install the rubber boot so that the mark Arrow B faces forward e Tighten Torque Tie Rod End Nuts 34 3 5 kgf m 25 ft lb e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots i
220. ena da NL E cep ton 5 14 Valve Clearance soi eniti o e da ts 5 14 valve Clearance Op 5 14 Valve REMOVA dte ae ente educ rote dur mulus X i v rb ete n PENAS 0 14 srirsidrziifo TEE UU Um 5 14 Valve Guide Removal esiste tene a dea S 5 15 Valve culde InstallatlOl c m n pie desds aput t tr abe 5 15 Seal INSPECCION ENTE TETTE 5 15 Valve Seat Repall av du pa ap uU 5 16 valve Spring Free LENGQUY ea 5 21 Valve Head 5 21 Valve Stem DIME lE 5 21 5 21 Measuring Valve Guide Clearance pp 5 22 Valve Stem Gap InsbeclOllzsuossi en ecu de 5 22 Exhaust Pipe and WU 5 23 Exhaust Pipe RemowVval ssseess ibus e he 5 23 REMOVA M mm 5 23 Exhaust Pipe and Muffler Installationm pp 5 24 Exhaust Pipe and Muffler Inspection 5 24 Spalk Atrester Cleaning t Hr 5 24 5 2 ENGINE TOP END Exploded View SS Sats 28 oo9 e F ENGINE TOP END 5 3 Exploded View 1 Oymder
221. end and bracket rear end are on the same line B Front C PO5011BS1 OWhen installing the right middle pipe A tighten the bolts and nuts as shown in the figure Front B e Replace the rear bar mounting nuts lower with new ones e Tighten Torque Rear Bar Mounting Bolts Upper 44 N m 4 5 32 ft lb Rear Bar Mounting Nuts Middle 44 4 5 32 ft lb Rear Bar Mounting Bolts Lower 64 6 5 47 16 e Install the removed parts see appropriate chapter P05012BS1 Center Bar Removal e Remove Rear Bar see Rear Bar Removal Top Bar Mounting Bolts A and Washers Top Bars B 16 24 FRAME Front Center and Rear Bars e Remove Seat Bar Mounting Bolts A and Washers Seat Bar B with Front Seat Back e Remove Front Bar Mounting Bolts Upper Side only Center Bar Mounting Bolts A Washers and Nuts Center Bar B Center Bar Installation e Replace the center bar mounting nuts with new ones e Tighten Torque Center Bar Mounting Bolts 64 N m 6 5 kgf m 47 ft Ib Top Bar Mounting Bolts 44 N m 4 5 kgf m 32 ft lb Seat Bar Mounting Bolts 64 Nm 6 5 kgf m 47 ft Ib e Route the fuel tank breather hose A and install its end into the steel clamp B on the center bar as shown in the figure e Install the removed parts see appropriate chapter Cargo Bed Latch Position Inspection e Cargo bed must be latched securely on the cargo bed or the rear seat
222. ep it after indicator light lights up OAfter 4 seconds the EPS warning indicator light LED goes off OEighth free the hands from the steering wheel after indi cator light goes off OAfter 4 seconds the EPS warning indicator light LED blinks two times This blink shows that the service code in the EPS ECU was erased If the EPS warning indicator light LED does not blink or lights up turn the main switch OFF and repeat from fourth procedure again NOTE OThe service code erase is same procedure as until eighth procedure STEERING 15 37 15 38 STEERING EPS Electric Power Steering System ONinth wait for 5 seconds after indicator light blinks two times OAfter 5 seconds the EPS warning indicator light LED blinks three times This blink shows that the EPS neutral position was registered If the EPS warning indicator light LED does not blink turn the main switch OFF and repeat from fourth proce dure again OLastly wait for 1 second or more after indicator light blinks three times and turn the main switch OFF e Disconnect the auxiliary lead from the terminals of the self diagnosis system connector e Start the engine and confirm that the EPS warning indi cator light LED lights up for 1 second and goes off e Confirm the EPS operates correctly STEERING 15 39 EPS Electric Power Steering System EPS Neutral Position Registration Flow Chart EN EPS Warming Indicator Light LED State Tu
223. er Panel Trim Run the main harness under the leads Main Harness Alternator Lead Brown Alternator Cable Red Starter Motor Lead Battery Cable to Engine Ground Battery Cable to Starter Motor Align the white tape of the harness with this clamp Band APPENDIX 18 21 A ANN 18081539814 C Parking Brake Switch Lead Starter Circuit Relay Preheating Timer Radiator Fan Relay Glow Plug Relay Run the branch of harness on right side of clamp Run the battery cables on the rub ber damper for the left rear brake line Front Upper Inside 18 22 APPENDIX Cable Wire and Hose Routing Alternator Lead Main Harness Battery Cable Battery Cable Battery Band Fuse Box 1 Fuse Box 2 Radiator Fan Breaker Yellow Mark Yellow Tape 1898160884 APPENDIX 18 23 Cable Wire and Hose Routing This page intentionally left blank 18 24 APPENDIX Cable Wire and Hose Routing KAF950G9 GC HA J Oe rt LU H b ker X Aral 8 9 i f 18081618844 Cable Wire and Hose Routing 5 Fuel Return Hose Fuel Output Hose Fuel Filter Fuel Pipes Fuel Tank Fitting Se
224. er ese dine tona tede eus du diu n utu tco de 16 34 FRE AE ETC SUID 16 35 Rear End S bframe Iermovals eva e ur 16 35 Rear End Subtrame Installatioli 16 35 FRAME 16 3 Exploded View This page intentionally left blank 16 4 FRAME Exploded View FRAME 16 5 Exploded View Ne Fee Battery Holder Mounting Nuts v 17 1 3 Stay Rod Rear e 90 6 KAF950G9 GC HA CA and EUR Models Apply grease on both surface Apply grease on the groove KAF950G9 GC HA Apply adhesive Apply grease Apply a non permanent locking agent Replacement Parts gt 16 6 FRAME Exploded View 1 02138885 FRAME 16 7 Exploded View e Fee ee center Bar Mounting Bos ea 65 4 2 Front Bar Mounting Botts Lower 98 100 723 3 Front Bar Mounting Botts Upper 44 45 32 _ 4 Front Seat Bar Mounting Bots 65 7 _ 5 Rear Bar Mounting Bolts ea 65 7 _ 6 Rear Bar Mounting Botts Upper 44 45 32 _ 7 Rear Bar Mounting Nuts Middle 44 45 32 Rear End Subframe Mounting Nus 44 as 32 R 9 Top 44 45 3 10 Reflector KAF950G9 GB CA Models 11
225. er lubricant 14 4 SUSPENSION Specifications em Stand Rear Shock Absorbers Spring Preload Setting Position 1st position Usable Range 1 5 positions SUSPENSION 14 5 Special Tool Steering Stem Nut Wrench 57001 1100 ST571100ST 14 6 SUSPENSION Struts and Rear Shock Absorbers Strut Front Shock Absorber Removal e Remove Glove Compartment see Glove Compartment Removal in the Frame chapter Front Wheel see Wheel Removal in Wheels Tires chapter Brake Panel see Brake Panel Assy Removal in the Brakes chapter Brake Hose Retainer A Brake Hose B from Bracket Cotter Pin Strut Clamp Bolt and Nut C e Remove the strut mounting locknuts A e Remove the strut A from the steering knuckle B Front C Strut Front Shock Absorber Installation e Insert the strut to the steering knuckle A while aligning the notch B on the strut with the clamp bolt hole C on the steering knuckle e Replace the strut mounting locknuts with new ones e Tighten Torque Strut Mounting Locknuts 44 N m 4 5 32 ft Ib Strut Clamp Nuts 98 N m 10 0 kgf m 72 3 ft Ib Struts and Rear Shock Absorbers e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nea
226. er this title prior to its sale and delivery to the ultimate 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 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 NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform 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 Addition of components or accessories that result in the vehicle exceeding the 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 THESE PROVISIONS OF FEDERAL LAW THE VI
227. eset the shoe clearance adjuster from the protruding position to its orig inal position The stop B sets the position Left Parking Brake Lever Linkage A of Rear Brake Ratchet B Protruding Position C Shoe Clearance Adjuster E Front F Left Parking Brake Lever Linkage A of Rear Brake Ratchet B Original Position D Shoe Clearance Adjuster E Front F e Apply brake fluid to the threads of the brake pipe nipple and tighten it Torque Brake Pipe Nipples 18 1 8 13 ft Ib Front Wheel Cylinder Mounting Bolts 10 3 N m 1 1 kgf m 91 in Ib Rear Wheel Cylinder Mounting Nuts 7 4 N m 0 75 kgf m 65 in Ib 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply grease to the following portions front and rear brake panels Brake Panel and Brake Shoe Contact Points A Wheel Cylinder Piston Ends B Brake Shoe Anchor Ends C OThe left front brake is shown Rear Brake Panel e Grease the shoe clearance adjuster pivots A Rear Brake Panel e Pack the gaps A with a little grease Front and Rear Brake Panels e Bleed the brake line after drum installation see Brake Line Air Bleeding in the Brakes chapter e Be sure to check the brake system for good braking power no brake drag and no fluid leakage WARNING After servicing it takes several applications of the brake pedal before the brake shoes contact the drum which could result in increased stopping distance
228. essory Terminal Main Switch Band EPS ECU Fuel Gauge Hour Meter EPS Warning Indicator Light LED Glow Plug Light Parking Brake Indicator Light Speedometer Cable Speedometer Illumination Coolant Temperature Warning Indicator Light Oil Pressure Warning Indicator Light Horn Button Light Switch Band To Left Headlight Band EPS Motor Connector Band EPS Torque Sensor Connector Band To Right Headlight Front Detail A Accessory Terminals Band Front Clamp Detail B Detail C 25 mm 0 98 in To Horn Switch APPENDIX 18 5 18 6 APPENDIX Cable Wire and Hose Routing W uv _ INA Pur ub 31 E E 2 1B68157BW4 Radiator Fan Motor Radiator Fan Motor Lead The band must be located in exact position as shown in the figure Radiator Fan Switch Lead 50 mm 1 97 in Horn Lead Clamp Front Final Gear Case Breather Hose Clamp Front Final Gear Case The cooling hose should be under the bracket of the frame Front View from Top APPENDIX 18 7 Cable Wire and Hose Routing 1 Hold the right brake hose with the harness 2 Right Brake Hose 3 Brake Master Cylinder 4 Keep the brake hose away from the EPS unit 5 Install the clamp in this direction 6 Left Brake Hose 7 Front 18 8 APPENDIX Cable Wire and Hose Routing EPS 40 A Fuse EPS 7 5 A Fuse
229. eter Standard 71 93 71 96 mm 2 8319 2 8331 in NOTE Olf the cylinder has been bored oversize use the over size piston diameter CRANKSHAFT CRANKCASE 9 31 Pistons and Crankcase Piston Cylinder Clearance e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 06 0 08 mm 0 0024 0 0031 in Service Limit 0 12 mm 0 0047 in x If the piston cylinder clearance is greater than the service limit and the cylinder inside diameter is not more than the service limit replace the piston x If only a piston is replaced the clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid piston seizure Cylinder Boring Honing When boring and honing a cylinder note the following OOversize pistons require oversize rings Oversize Piston and Rings 0 25 mm 0 0098 in Oversize OBefore boring a cylinder first measure the exact diam eter of the oversize piston and then according to the standard clearance in the specifications determine the rebore diameter However if the amount of boring nec essary would increase the inside diameter by more than 0 25 mm 0 0098 in the crankcase must be replaced OCylinder inside diameter must not vary more than 0 01 mm 0 00039 in at any point OBe wary of measurements taken immediately after boring since the heat affects cylinder diameter t
230. eter of the piston pin bore x If the inside diameter exceeds the service limit replace the piston Piston Pin Bore Diameter Service Limit 18 03 mm 0 7098 in e Measure the outside diameter of the piston pin x If the outside diameter is less than the service limit re place the piston pin Piston Pin Diameter Service Limit 17 98 mm 0 7079 in KE08012B31 TRANSMISSION 10 1 Transmission Table of Contents EXploded qute ef idi CANONS EE O ETE Special Tools e e Transmission Transmission Oil Level Inspection TRANSMISSION RT Transmission CaS Enr 5 Transmission Case REMOVA VL DAT Transmission Case Installation Transmission Gase SDpIItHlli 555 osculo iem uiae Transmission Case iier cede la A Transmission and I Transmission and Hi Low Shift Cables Installation Lever Position JhSDectlolTuasessericeetuiri event DE OR eub
231. eter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 327 607 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact ENGINE TOP END 5 17 8 15011981 8 15012181 5 18 ENGINE TOP END Valves x If the outside diameter A of the seating surface is too large make the 327 grind described below the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 327 angle B until the seat outside diameter is within the specified range OTo make the 327 grind fit a 32 cutter into the holder and slide it into the valve guide OTu
232. evel too high Engine oil viscosity too high Drive train trouble Brake dragging Converter and or belt excessive heating Belt dirty or worn Drive or driven pulley sheave dirty or worn Driven pulley spring broken or weak Drive pulley spring broken or weak Idle speed too high Converter fan damaged Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Front final gear case overheating Insufficient oil Bevel gears maladjusted LSD clutches maladjustment Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Radiator fan switch trouble Thermostat trouble Converter Operation Faulty Belt slipping Belt dirty or worn Drive or driven pulley sheave dirty or worn Driven pulley spring broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt drive or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly in stalled too loose Sh
233. ews A e Remove the water pipe bracket bolts e Remove the water pipe bracket bolt A e Remove Propeller Shaft Bearing Housing Mounting Bolts A and Nuts Washers Collars Propeller Shafts e Move the water pipe A and the propeller shaft bearing housing B to the outside C e Remove Rear Propeller Shaft D Front Propeller Shaft Propeller Shaft Installation e Wipe the old grease off the splines of the propeller shafts and grease to them e Inspect the propeller shafts see Propeller Shaft Inspec tion e Replace the O ring A with a new one e Apply grease to the new O ring on the front pinion gear e Install the front propeller shaft yoke B on the pinion gear e Put the propeller shaft bearing housing C at fully outside position e Install the rear propeller shaft yoke D on the rear driven gear shaft so that the thin side E of the propeller shaft positions to the rearward e Install the rear propeller shaft yoke on the front pro peller shaft rear end aligning the yoke angles of the front and rear propeller shafts e Parallel I the propeller shaft bearing housing J with the mounting bracket K OMake the 3 mm 0 12 in clearance L between the yoke B of the front propeller shaft and the front pinion gear nut M e Replace the propeller shaft bearing housing nuts Q with new ones e Install Propeller Shaft Bearing Housing Bolts N Washers O Collars P
234. explosive under certain conditions Turn the main switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTICE Take care to prevent any dirt from entering injection nozzle holes or delivery valve ports when fuel deliv ery lines are removed FUEL SYSTEM 3 15 3 16 FUEL SYSTEM Fuel Injection Pump e Cut the bands A e Remove Air Duct Mounting Screw B Air Duct C e Remove the air duct A e Remove Fuel Injection Pipe Clamp Bolts A Fuel Injection Pipe Clamps B e oosen the fuel injection pipe upper nuts e Remove Fuel Injection Pipe No 3 Lower Nut A and Upper Nut Fuel Injection Pipe No 1 Lower Nut B and Upper Nut Fuel Injection Pipe No 2 Lower Nut C and Upper Nut Fuel Injection Pipe Installation e Install the fuel injection pipes using the following steps OFirst install the No 2 injection pipe A OSecondly install the No 1 injection pipe OFinally install the No 3 injection pipe NOTE OTighten the upper and lower nuts temporarily and then tighten them to the specified torque e Tighten Torque Fuel Injection Pipe Mounting Nuts 25 2 5 kgf m 18 ft Ib Fuel Injection Pipe Clamp Bolts 7 4 N m 0 75 kgf m 65 in Ib Fuel Injection Pump Fuel Injection Pump Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Fuel Inje
235. ey Wrench 57001 1549 e Remove the spider with the movable sheave e Remove Spider A Shoes B Nuts C Ramp Weight Pin D Ramp Weight E Movable Sheave F Fixed Sheave G IF06042B32 Drive Pulley Inspection x If the sheave surfaces A appear damaged replace the sheaves 6 18 CONVERTER SYSTEM Drive Pulley e Replace any sheave which has uneven wear on the belt contacting surface Sheave Surfaces A Straight Edge B 1 08003 81 x If the cover bushing is damaged or worn replace the drive pulley cover Cover Bushing Inside Diameter A Standard 27 655 27 955 mm 1 089 1 101 in Service Limit 27 99 mm 1 102 in x If the sheave bushing is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 38 055 38 155 mm 1 498 1 502 in Service Limit 38 19 mm 1 504 in x If the spider shoes A are damaged replace them e Check the spider shoe side clearance see Spider Shoe Side Clearance Adjustment P the ramp weights A are damaged or worn replace them x If the pins B are damaged replace them CONVERTER SYSTEM 6 19 Drive Pulley x If the ramp weights are damaged or worn replace them Rump Weight Bushing Inside Diameter A Standard 7 000 7 091 mm 0 276 0 280 in Service Limit 7 23 mm 0 28 in IF06040BS1 x If the rollers A are damaged or worn replace the spider B x If the washers C are damaged or worn replace
236. flammable and can be explosive under certain conditions Turn the main switch off Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Front Seat Lower Cover Front and Rear see Floor Cen ter Panel Removal in the Frame chapter Fuel Tank Cap A Screws B Front Seat Lower Cover Right C For KAF950G9 GC HA e Remove Clamps and Fuel Hoses A Clamp and Air Vent Hose B Bolt C and Washer e Remove Bolt A Washer and Nut Bolt B and Washer Fuel Tank C For KAF950GD e Disconnect the fuel level gauge lead connector e Remove the clamps and fuel hoses A FUEL SYSTEM 3 33 Fuel Tank e Remove the clamp A and air vent hose B e Remove the bolt A and washer e Remove Bolt A Washer and Nut Bolt B and Washer Fuel Tank C Fuel Tank Installation e Check that the dampers A are in place on the fuel tank B KAF950G9 GA HA C KAF950GB 15118058 P 1011014881 3 34 FUEL SYSTEM Fuel Tank e Replace the nut G with a new one e Install the dampers A in the fuel tank as shown in the figure Thicker Side B Front Side C Collars D Washers E Bolts F Nut I KAF950G9 GC HA J KAF950GD IC11019B32 IC11020B32 FUEL SYSTEM 3 35 Fuel Tank e Install the check valve A so that the arrow B faces fuel tank Black Color C Blue Colo
237. flash point solvent Install the brake shoe springs on the original positions see Brake Shoe Spring Inspection OThe parking brake lever linkage has a brake shoe clear ance adjuster e Push the ratchet A forward and then in to reset the shoe clearance adjuster from the protruding position to its orig inal position The stop B sets the position Left Parking Brake Lever Linkage A of Rear Brake Ratchet B Protruding Position C Shoe Clearance Adjuster E Front F Left Parking Brake Lever Linkage A of Rear Brake Ratchet B Original Position D Shoe Clearance Adjuster E Front F e Pack gaps A with grease sparingly e Install the brake shoe springs on the original positions see Brake Shoe Spring Inspection BRAKES 13 19 13 20 BRAKES Brake Panel Assemblies Front and Rear Brake Panels e Bleed the brake line after drum installation see Brake Line Air Bleeding e Be sure to check the brake system for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake pedal before the brake shoes contact the drum which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum e Inspect the parking brake lever inspection see Parking Brake Lever Inspectio
238. following ORun the harness cables and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Glove Compartment Removal e Remove Control Panel see Control Panel Removal Screws A Glove Compartment B 16 18 FRAME Front Cargo Compartment Front Cargo Hood Removal e ilt up the cargo hood A e Remove Cargo Hood Mounting Bolts B and washers Cargo Hood Front Cargo Hood Installation x If the dampers A are removed from the front cargo hood B install them as follows 0 5 mm 0 0 20 in C 2 5 0 08 0 20 in D 1 099001882 e Installation is the reverse of removal note the following OContact the bracket A of the front cargo hood and the boss B of the arm C PO8006BS1 FRAME 16 19 Front Cargo Compartment xIf the hook bracket was removed from the front cargo hood install it as follows OTighten the bolts A while pushing the bracket B forward C Front Cargo Hood Cable Adjustment e Remove the front cargo compartment see Front Cargo Compartment Removal e Loosen the adjuster mounting nuts A and slides the ad juster as shown in the figure 20 5 21 5 mm 0 81 0 85 in B e Tighten the adjuster mounting nuts securely Front Cargo Compartment Removal e Remove Front Fenders see Front Fender Removal Coolant Reserve Tank see Coolant Reserve Tank Re moval in the Cooling System chapter e Remove Screws A and Collars
239. ft Bearing Housing Cover Bolts 3 4 0 35 30 in Ib Propeller Shaft Inspection e Visually inspect the splines of the propeller shafts x If they are twisted badly worn or chipped replace the shafts e Check that the universal joint works smoothly without rat tling or sticking x If it does not the bearings of the joint are damaged Re place the propeller shaft with a new one 12 34 FINAL DRIVE Drive Shaft and Axles Front Axle Removal e Remove Steering Knuckle see Steering Knuckle Removal in the Steering chapter Front Axle Cap Bolts A Front Axle B Front Axle Installation e Wipe the old grease off the splines of the axle and cap oil seal and grease them e Inspect the axle see Drive Shaft and Axle Inspection e Be sure to install the spacer A and O ring B in the re cess of the front final gear case e lighten Torque Front Axle Cap Bolts 8 8 N m 0 90 kgf m 78 in Ib Rear Drive Shaft and Axle Removal e Remove Rear Wheels see Wheel Removal in the Wheels Tires chapter Rear Brake Drums see Brake Drum Removal in the Brakes chapter Rear Brake Panel Assemblies with Brake Pipes and Hoses Leaf Springs see Leaf Spring Removal in the Suspen sion chapter Rubber Bands A Axles B and Axle Bracket C e Slide the dust boots D from the drive shafts E and pull the one of the axles from the drive shaft and then the other axle from the shaft e ap A the outside of the re
240. g Condition Inspection Conventional Type Battery e Refer to the Charging Condition Inspection Conventional Type Battery in the Periodic Maintenance chapter Initial Charging Conventional Type Battery DANGER Batteries produce an explosive gas mixture of hy drogen and oxygen that can cause serious injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This proce dure prevents sparks at the battery terminals which could ignite any battery gases NOTICE Charging the battery at a rate higher than speci fied may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charg ing rates also cause the plates to shed active mate rial Deposits will accumulate and can cause inter nal shorting If the temperature of the electrolyte rises above 45 113 F during charging reduce the charging rate to lower the temperature and increase charg ing time proportionately ELECTRICAL SYSTEM 17 27 10080128851 17 28 ELECTRICAL SYSTEM Battery e Remove Battery see Battery Removal Filler Caps see Electrolyte Level Inspection Conven tional Type Battery A WARNING Electrolyte contains sulfuric acid which is harmful to skin eyes and clothing Wear eye protection and rubber gloves If spillage
241. h Installation Troubleshooting Guide Engine RPM too low Wrong viscosity oil Wrong viscosity or diluted oil Plugged oil galleries Low oil level Broken relief valve spring Missing relief valve plunger Worn bearings Damaged or defective oil pump ENGINE LUBRICATION SYSTEM 7 13 Pressure Switch Oil Pressure Switch Removal e Drain the engine oil see Engine Oil and or Oil Filter Change in the Periodic Maintenance chapter e Remove Fuel Injection Pipes see Fuel Injection Pipe Removal in the Fuel System chapter Oil Level Gauge Pipe A see End Plate Removal in the Crankshaft Crankcase chapter Bolt B Plate C Switch Connector D Oil Pressure Switch E Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque Oil Pressure Switch 14 N m 1 4 kgf m 10 16 e Install the removed parts see appropriate chapters 7 14 ENGINE LUBRICATION SYSTEM Cil Nozzle Oil Nozzle Installation e Refer to the Timing Gear Case Installation in the Crank shaft Crankcase chapter ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents woes 8 2 OS Gl alls OOD E 8 4 ENGINE IRemoval nstallatiOFi iussa eae dass arse oo et 8 5
242. h the battery B 10 resistor C and hand tester D as shown in the figure e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 e race A each side of the speed sensor surface with the screwdriver OThen the tester indicator should flick B x If the tester indicator does not flick replace the speed sensor GP18255BS1 17 66 ELECTRICAL SYSTEM Fuses Fuse Removal e ilt up the front seat e Unlock the hook A and remove the fuse box cover B e Pull the fuses A straight out of the fuse box Fuse Installation e Install the fuse cover A so that the yellow mark B faces left side of the vehicle 50 A Fuse Removal e ilt up the front seat e Unlock the stopper A and pull the 50 A fuse B straight out of the fuse box Fuse Installation x If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the fuse box fuses on the original position as spec ified on the lid ELECTRICAL SYSTEM 17 67 Fuses Fuse Inspection e Remove the fuse see Fuse Removal e Inspect the fuse element OFor 50 A fuse there is window for inspection in the upper surface x If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related componen
243. haft A OTake care when installing the camshaft to prevent dam aging the cam bearings journals and lobes e Install Camshaft Retainer Camshaft Retainer Bolts Torque Camshaft Retainer Bolts 7 8 N m 0 80 kgf m 69 e Install the camshaft drive gear A OFit the groove B in the camshaft drive gear onto the key on the camshaft OAlign the marks C on the camshaft drive gear and idle gear marked when removing Olf the idle gear is turned set the timing gears to the original positions see Timing Gear Case Installation e Move the flywheel holder A to the forward side of the engine to hold the crankshaft Special Tool Flywheel Holder 57001 1438 e Tighten Torque Camshaft Drive Gear Bolt 43 4 4 kgf m 32 ft lb e Install the removed parts See appropriate chapters CRANKSHAFT CRANKCASE 9 17 Camshaft Camshaft Inspection e Measure the overall height A of each cam If any cam has worn past the service limit replace the camshaft Cam Height Standard Inlet 30 065 30 135 mm 1 1837 1 1864 in Exhaust 30 065 30 135 mm 1 1837 1 1864 in Service Limit Inlet 29 965 mm 1 1797 in Exhaust 29 965 mm 1 1797 in e Measure the diameter of the camshaft journals If any journals has worn past the service limit replace the camshaft Camshaft Journal Diameter Standard Right Side A 35 959 35 975 mm 1 4157 1 4163 in Center B 35 910 35 9
244. hapter Oil Pan Bolts A and Nuts B e Remove the oil pan C straight so that the baffle plate in the oil pan does not to hitch the oil strainer e Remove Oil Strainer Mounting Bolt A and Nuts B Oil Strainer C Oil Pan and Oil Strainer Installation e Clean the oil pan and oil strainer thoroughly whenever they are removed e Replace the oil strainer gasket A with a new one e Tighten Torque Oil Strainer Mounting Bolt and Nuts 7 8 0 80 kgf m 69 in Ib e Apply liquid gasket A to the mating surface as shown in the figure Sealant Three Bond 1207F e Install the oil pan B so that the baffle plate C does not hitch the oil strainer e Tighten Torque Pan Bolts and Nuts 7 8 N m 0 80 kgf m 69 in Ib Oil Strainer Cleaning Inspection e Clean the oil strainer and remove any particles stuck to it NOTE OWhile cleaning the strainer check for any metal parti cles that might indicate internal engine damage e Check the screen A carefully for any damage holes and broken wire x If the screen is damaged replace the oil strainer 4 7 10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Remove Timing Gear Case see Timing Gear Case Removal in the Crankshaft Crankcase chapter Oil Pump Outer Rotor A Oil Pump Installation e Clean and lubricate the oil pump outer rotor A with en gine oil e Apply engine oil to the oil pump outer rotor e Install the oil pump oute
245. he other end B Both ends are put into the cylinder OCheck that there is no grease or any oil on the brake shoe x If there is grease or any oil the brake shoe clean off them with a high flash point solvent e Install the brake shoe springs on the original positions see Brake Shoe Spring Inspection Rear Brake Panel e Apply lithium grease NLGI Grade No 2 to the following portion Brake Panel Seating Surface Between Axle and Panel e Install the brake panel and wheel cylinder e Apply grease to the shoe clearance adjuster pivots A e Apply a non permanent locking agent to the threads of the brake panel mounting bolts e Tighten Torque Rear Brake Panel Mounting Bolts 44 N m 4 5 kgf m 32 ft lb Rear Wheel Cylinder Mounting Nuts 7 4 0 75 65 in Ib e Apply brake fluid to the thread of the brake pipe nipple and tighten it Torque Brake Pipe Nipples 18 N m 1 8 13 ft Ib e Apply grease to the following portions refer to front brake above Contact Points of Brake Panel and Brake Shoes Wheel Cylinder Piston Ends Brake Shoe Anchor Ends Brake Panel Assemblies e Install the parking brake lever linkage A and the grommet B with the tabs C up e Fit the lips D of the grommet as shown in the figure Brake Panel E top view of the left rear OCheck that there is no grease or any oil on the brake shoe x If there is grease or any oil on the brake shoe clean off them with a high
246. he Engine Top End chapter Oil Level Gauge Pipe see End Plate Removal in the Crankshaft Crankcase chapter Torque Converter Case see Torque Converter Case Re moval in the Converter System chapter e Turn the crankshaft pulley A clockwise and position the crankshaft at 1 piston TDC on the compression stroke OAlign the timing mark B on the crankshaft pulley and reference point C on the timing case cover Olf the inlet and exhaust valves for 1 cylinder have no clearance turn the crankshaft pulley one revolution e Remove the distributor bolt A Fuel Injection Pump e Install the dial gauge adapter A and dial gauge B Special Tool Dial Gauge Adapter 57001 1430 e Slowly turn the crankshaft pulley counterclockwise about 30 until the dial gauge needle stops Pump plunger lift is zero at this point e Set the dial gauge to the 0 position e Slowly turn the crankshaft pulley clockwise stopping at 1 piston TDC on the compression stroke NOTE ODo not turn the crankshaft pulley past TDC If the crank shaft pulley is turned past TDC turn the crankshaft back to 0 on the dial gauge and repeat the procedure e Note dial gauge reading Injection Timing Plunger Stroke Marking of Injection Nozzle Red or Green 0 81 0 03 mm 0 0319 0 0012 in None 0 81 0 02 mm 0 0319 0 0008 in x If the gauge reading is within the specification the injec tion pump is properly timed x If the gauge read
247. he case of a rebored cylinder and oversize piston the service limit for the cylinder is the diameter that the cylin der was bored to plus 0 1 mm 0 0039 in and the service limit for the piston is the oversize piston original diameter minus 0 15 mm 0 0059 in If the exact figure for the re bored diameter is unknown it can be roughly determined by measuring the diameter at the base of the cylinder Camshaft Bearing Replacement e Remove the timing gear case see Timing Gear Case Re moval Using the camshaft bearing remover A remove the camshaft bearing Special Tool Camshaft Bearing Remover 57001 1435 9 32 CRANKSHAFT CRANKCASE Pistons and Crankcase e Install the new camshaft bearing A OFace the notch B in the bearing to the outside and align the oil holes C in the bearing and crankcase e Using the camshaft bearing driver A install the camshaft bearing Special Tool Camshaft Bearing Driver 57001 1434 Camshaft Plug Replacement e Remove Timing Gear Case see Timing Gear Case Removal Camshaft Plug A OUse a wooden dowel or brass rod to prevent damage to the camshaft bearing e Using the camshaft bearing driver A install a new camshaft plug Special Tool Camshaft Bearing Driver 57001 1434 Piston Ring and Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to the groove sur faces If not replace the piston an
248. he rubber dampers note the following Olnstall the rubber dampers so that the thin thickness side faces up ODo not apply a rubber lubricant e Install the EPS unit so that the EPS torque sensor A faces upside e Install the EPS unit mounting bolts B and tighten them temporary e Install the lower universal joint C to the shaft of the EPS unit e Install the universal joint clamp bolt D while aligning the notch on the shaft of the EPS unit with the clamp bolt hole on the lower universal joint and tighten it temporary E KAF950G9 GC HA F KAF950GD STEERING 15 53 1008091851 15 54 STEERING EPS Electric Power Steering System e Install the rubber boot A on the shaft B of the steering gear assembly temporary e Install the shaft of the steering gear assembly to the lower universal joint C e Install the universal joint clamp bolt D while aligning the notch on the shaft of the steering gear assembly with the clamp bolt hole on the lower universal joint and tighten it temporary e Install Rubber dampers E Brackets F e Apply non permanent locking agent to the steering gear assembly bracket bolts G and tighten them evenly Torque Steering Gear Assembly Bracket Bolts 52 N m 5 3 kgf m 38 ft lb e Tighten the EPS unit mounting bolts to the specified torque Torque EPS Unit Mounting Bolts 20 N m 2 0 kgf m 15 ft Ib H KAF950G9 GC HA KAF950GD e Install the rubber boot
249. hooks A without rattling Latch B x If there is rattling or not snug enough adjust the latch positions FRAME 16 25 Front Center and Rear Bars Cargo Bed Latch Position Adjustment e Release the mounting bolts A e Reposition the latch to the suitable place by sliding within the ellipse bolt holes e Retighten the mounting bolts NOTE OAdjustment must be made on both sides 16 26 FRAME Guard Front Guard Removal e Remove Screws A and Collars KAF950G9 GC HA Front Guard Cover B KAF950G9 GC HA e Remove Left and Right Front Guard Bolts A Upper Front Guard Bolts B and Nuts Lower e Remove the front guard C D KAF950G9 GC HA E KAF950GD Front Guard Installation e Installation is the reverse of removal note the following OReplace the nuts lower with new ones Fenders Front Fender Removal e Remove Screws A and Collars Rivets B e Clear the hook portion C from the slot and remove the front fender D Front Fender Installation OCheck that the clip nuts A are in place as shown in the figure e nsert the hook portion A into the slot B of the front fender e Install the front fender note the following parts A B C size Screws A L 16 mm 0 63 in and Collars L 4 mm 0 16 in Screw L 22 mm 0 87 and Collar L 6 mm 0 24 in Tapping Screw C L 20 mm 0 79 in and Collar L 9 5 mm 0 37 in Quick
250. ifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Driven pulley spring incorrect installed too tight Driven pulley movable sheave doesnt move smoothly Gear Shifting Faulty Doesn t go into gear Shift arm bent or seized Gear stuck on the shaft Shift cable maladjusted Shift cable lubrication inadequate Shift cable damaged Jumps out of gear Shifter groove worn Gear dogs worn Shift arm positioning bolt spring weak or broken Shift block worn Transmission shaft and or gear splines worn Shift cable maladjusted Overshifts Shift arm positioning bolt spring weak or broken Shift cable maladjusted Abnormal Engine Noise Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Fuel injection nozzle incorrect Overheating Troubleshooting Guide Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm push rod runout excessive Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure or damaged Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mount loose Cra
251. igure Special Tool Flywheel Holder 57001 1438 e Wipe off the excessive oil stuck on the tapered areas of the pulley and its engaging area with a ragged cloth be fore installation e Install the crankshaft pulley A and bolt OFit the hole B in the crankshaft pulley on the pin C in the crankshaft gear e Apply thin coat of engine oil to the threads of tightening bolt Do not apply excessive oil to its threads e Tighten Torque Crankshaft Pulley Bolt 98 10 0 kgf m 72 3 ft Ib e Install the removed parts see appropriate chapters e Adjust the fuel injection pump timing see Fuel Injection Pump Timing Inspection in the Fuel System chapter Timing Gear Case Cover Oil Seal Replacement e Remove Timing Gear Case Cover see Timing Gear Case Re moval Oil Seal A e Replace the oil seal with new one e Apply grease to the new oil seal e Press in the oil seal with the manufacturer s marks facing out Special Tool Timing Gear Cover Oil Seal Driver A 57001 1436 CRANKSHAFT CRANKCASE 9 13 Timing Gear Case Timing Gear Inspection e Inspect the timing gears using the following sequence e Check the timing gear backlash between the idle gear A and crankshaft gear B e Remove Camshaft Drive Gear see Timing Gear Case Removal Fuel Injection Pump Drive Gear see Timing Gear Case Removal Oil Pump Drive Gear see Timing Gear Case Removal OSet the tip of the dial gauge C on the idle
252. ing is not within the specification adjust the injection pump timing see Fuel Injection Pump Timing Adjustment Fuel Injection Pump Timing Adjustment Inspect the fuel injection pump timing NOTE ODo not turn the crankshaft pulley past TDC If the crank shaft pulley is turned past TDC turn the crankshaft back to 0 and repeat the procedure FUEL SYSTEM 3 19 3 20 FUEL SYSTEM Fuel Injection Pump e oosen the fuel injection pump mounting nuts A icIzBOIS P e oosen the fuel injection pump bracket bolt A e While observing the dial gauge slowly rotate the fuel in jection pump away from the cylinder head until gauge reads 0 81 0 03 mm 0 0319 0 0012 in e Hold the fuel injection pump in this position and tighten the fuel injection pump mounting nuts NOTE not rotate the pump past the specification If the pump is rotated past the specification rotate the pump back toward the cylinder head and repeat the proce dure e Tighten Torque Fuel Injection Pump Mounting Nuts 20 N m 2 0 15 ft Ib Fuel Injection Pump Bracket Bolts 20 N m 2 0 15 ft Ib e verify that the timing is correct turn the crankshaft pul ley counterclockwise until the dial indicator reads 0 e Then turn the crankshaft pulley clockwise until the timing mark on the crankshaft pulley aligns with reference point on the timing case cover e he indicator should be within the specification
253. install the O rings during adjust ment OCheck the backlash during tightening of the ring gear cover bolts and stop tightening them immediately if the backlash disappears Then change the ring gear shim to a thinner one e Set up a dial gauge against the ditch portion A of the pinion gear slotted nut B to check gear backlash shown e o measure the backlash move the pinion gear back and forth while holding the left front axle ring gear side steady The difference between the highest and the low est gauge reading is the amount of backlash e Measure the backlash at four locations of the nut 1104057 81 12 18 FINAL DRIVE Front Final Gear Case x If the backlash is not within the limit replace the ring gear shims To increase backlash decrease the thickness of the shim s To decrease backlash increase the thick ness of the shim s OChange the thickness a little at a time e Recheck the backlash and readjust as necessary e Move the pinion gear A back and forth Dial Gauge B Bevel Gear Backlash Standard 0 14 0 69 mm 0 0055 0 0271 in at ditch portion of the pinion gear slotted nut Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the pinion gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OTh
254. irst fit the circlip onto the shaft C and then expand it just enough to install Hence use a suitable gear to push the circlip into place e Install the collar e Install the speedometer gear B so that the stepped side C faces to the inside e Install the new circlip Special Tool Outside Circlip Pliers 57001 144 e Install the shifter so that the dogs A face to the outside e Insert the shift shaft A in the gear case e Replace the O ring B with a new one e Install the new O ring and apply molybdenum disulfide grease to it 1J08003BS1 e When the hi low gear case installing refer to the Hi Low Gear and Shift Mechanism Installation 10 28 TRANSMISSION 2WD AWD Shift Mechanism e Push the shift shaft A as shown in the figure e Install Washer B Shift Shaft Stop Bolt C e Tighten Torque Shift Shaft Stop Bolts 7 8 N m 0 80 kgf m 69 in Ib e Wipe off any protruding grease e Install the spring A e Turn the shift shaft B counterclockwise until it is stop and hold it e Install the shift shaft lever C on the shift shaft so that the center of the lever hole aligns with the mark D as shown in the figure e Tighten the shift shaft lever mounting nut E e Hook the spring end e Check that each gear and shifter spins or slides freely on its shaft without binding after assembly 2WD 4WD Shift Mechanism Inspection e Visually inspect the following parts Dogs on Shifter A
255. it replace the shoe B Wear Shoe Width Service Limit 16 4 mm 0 65 in 1 07008 81 Converter Air Cleaner Element Cleaning Inspec tion NOTE dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element e Remove the air cleaner element see Air Cleaner Element Removal in the Converter System chapter e Separate the foam element A from the paper element B e Clean the foam element in a bath of a high flash point solvent and then dry it with compressed air or by shaking it e After cleaning saturate the foam element with SE class oil squeeze out the excess then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the foam element e Clean the paper element by tapping gently NOTICE Do not use compressed air to clean the paper ele ment Do not oil the paper element PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Engine Lubrication System Engine Oil and or Oil Filter Change e Warm up the engine so that the oil wil
256. itch Color Code Black Brown Green GY Gray LB Light Blue LG Light Green 0 Orange P Pink PU Purple Red W White Yellow W2R0544BW5 17 16 ELECTRICAL SYSTEM Wiring Diagram KAF950GD Fuel Level Gauge Accessory Connector 12V 120W Power Outlet Lr BR 8BR W I si Parking Brake BK Y mox Po oe aie Radiator Light n our n Fan Switch I Ir Breaker x CO X 3 x lA An 15 Zel X ay HN D ToT vr Speedometer R BL Illumination 12V1 7W ler TF x 011 Pressure Warning E Indicator Light 12V1 7W e Glow Plug Light 12V1 7W BK Y Coolant Temperature Warning BR BR Indicator Light 12V3W Ue wG Hh Parking Brake R Indicator Light 12V3W R G BK Y Light BK R Y Switch Y BK BL Y v Main Switch BK W BK W ain Swite TEE UU W R W R 0 EY Terminals lt 6 1 W R R BK t BK Y Headlights gt 7 12V35WX2 i R BK BK Y BK L 8k Steering Shaft Component Brake Light Cs BR ass BL W BL Horn Button Steering Gear Assembly Radiator Fan Switch i Radiator Fan ir cum BK Y MAIN SWITCH CONNECTIONS Color BK YW BKBK W BR OFF e T 4 m Battery LS 12V52
257. k as specified the switch is de fective Replace the starter switch Testing Switch Criteria When battery is connected Pinion gear must move outward quickly When battery is disconnected Pinion gear must return quickly Starter Circuit Relay Inspection e Remove Mounting Rivets A Screws B Front Seat Lower Cover Left C e Remove Starter Circuit Relay Connector A Starter Circuit Relay B ELECTRICAL SYSTEM 17 45 17 46 ELECTRICAL SYSTEM Electric Starter System e Connect the hand tester A and 12 V battery B to the starter circuit relay C as shown in the figure Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected 0 O When battery is disconnected Q Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Electric Starter Circuit 10811022882 Starter Circuit Relay Main Switch Neutral Switch Battery etarter Motor Main Fuse 30 A Fuse 2 Starter Relay Fuse 30 A Fuse Box 1 gt Preheating System Glow Plug Removal e ilt up the cargo bed e Remove the caps A e Remove Connecting Plate Nuts A Connecting Plate B Glow Plug Lead C e Remove the glow plug A Glow Plug Installation e Tighten Torque Glow Plugs 17 N m 1 7 kgf m 13
258. ke drag and no fluid leakage WARNING After servicing it takes several applications of the brake pedal before the brake shoes contact the drum which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake pedal is obtained by pumping the pedal until the shoes are against the drum e Inspect the parking brake lever inspection see Parking Brake Lever Inspection in the Periodic Maintenance chap ter Brake Panel Disassembly Front Brake Panel e Remove Front Brake Drum see Brake Drum Removal Brake Pipe Nipple and Vent Hose see Brake Panel Assy Removal e Remove the brake shoe springs A e While pushing the shoe hold down spring B turn the pin C 90 and remove the shoes D individually NOTE OWrap the brake shoes with a clean cloth to protect the linings from grease or dirt e Remove the brake panel mounting bolts E and then re move the brake panel F Front G B BRAKES 13 17 Brake Panel Assemblies Rear Brake Panel e Remove Rear Brake Drum see Brake Drum Removal Vent Hose A Grommet B of Parking Brake Lever Linkage Brake Pipe Nipple C Unscrew Front D Immediately wipe up any brake fluid that spills NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately e Remove the brake shoe springs A e
259. king the tooth contact pattern FINAL DRIVE 12 19 12 20 FINAL DRIVE Front Final Gear Case Correct Tooth Contact Pattern No adjustment is required Heel Bottom Bottom Bottom Pinion Gear Top Heel X eee Y Bottom Incorrect Tooth Contact Patterns Example 1 Decrease the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Bottom Heel To Bottom j Toe Bottom Bottom Pinion Gear Heel Ring Gear Example 2 Increase the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Bottom bow Bottom Pinion Gear Toe T Heel id x Bottom Ring Gear FINAL DRIVE 12 21 Front Final Gear Case Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged Differential Gear Inspection e Visually check the differential gears A for scoring chip ping or other damage e Also inspect the differential pinion gear shaft B and gear housing C where the differential gears rub x If they are scored discolored or otherwise damaged re place them as set E Tapered Roller Bearing Inspection e Visually inspect the bearings A for abrasion
260. l 6 6 CONVERTER SYSTEM Specifications tem _ Standard Drive Belt Belt Width 34 1 mm 1 34 in 32 6 mm 1 28 in Belt Deflection 28 36 mm 1 10 1 42 in Drive Pulley Cover Bushing Inside Diameter 27 655 27 955 mm 1 089 1 101 27 99 mm 1 102 in Sheave Bushing Inside Diameter 38 055 38 155 mm 1 498 1 502 in 38 19 mm 1 504 in Ramp Weight Bushing Inside Diameter Spring Free Length 77 mm 3 03 in Shoe Side Clearance 0 05 0 20 mm 0 0020 0 0079 in Driven Pulley Movable Sheave Bushing Inside 40 mm 1 5 in Diameter Wear Shoe Width 16 4 mm 0 65 in opring Free Length 137 5 mm 5 41 in m 7 000 7 091 mm 0 276 0 280 in 7 23 mm 0 28 in CONVERTER SYSTEM 6 7 Special Tools Outside Circlip Pliers Drive amp Driven Pulley Holder 57001 144 57001 1473 875701445 875714735 Bearing Driver Set Drive Pulley Holder 57001 1129 57001 1548 875711295 ST5715488T Drive amp Driven Pulley Holder Drive Pulley Wrench 57001 1412 57001 1549 35 488 C 4 8 75714125 ST5715498T Drive Puller Bolt Flywheel amp Pulley Holder 57001 1429 57001 1605 ST5714298T ST5716058T Driven Pulley Holder 57001 1465 8 75714655 6 8 CONVERTER SYSTEM Air Cleaner Air Cleaner Housing Removal e oosen Clamps A e Remove Air Ducts B C KAF950G9 and KAF950GA HA early models D KAF950GA HA
261. l 57001 1236 Deep Socket Wrench C Special Tool Socket Wrench Hex 22 57001 1236 Torque Alternator Pulley Locknut 11 N m 1 1 97 in Ib Alternator Operational Inspection e Check the battery condition Conventional Type Battery see Charging Condition Inspection Conventional Type Battery in the Periodic Maintenance chapter Sealed Type Battery see Charging Condition Inspection Sealed Type Battery NOTE OAlways check the battery condition before condemning the alternator The battery must be fully charged in or der to conduct accurate alternator inspection e Check the wiring see Wiring Inspection e Warm up the engine to bring the components up to their normal operating temperatures e Stop the engine e Remove the 30 A main fuse see Fuse Removal e Connect the hand tester A range DC 25 V and ammeter B range DC 40 A after the engine start as shown in the figure Battery C 50 A Fuse D Alternator E Load F e Measure the alternator output voltage and amperage at 2 000 rpm with the light switch turned OFF Alternator Output Voltage Standard 13 3 14 8 V at 25 C 77 F Alternator Output Amperage no load Standard 10 A or less e Stop the engine e Install the 30 A main fuse see Fuse Installation e Measure the alternator output voltage and amperage at 2 000 rpm with the light switch turned ON Alternator Output Voltage Standard 13 3 14 8 V at 25 C 77 F A
262. l pick up any sedi ment and drain easily e Place an oil pan beneath the engine e Remove the engine oil drain plug A and let the oil drain completely x If the oil filter is to be changed replace it with a new one see Oil Filter Removal Installation e Replace the gasket with a new one e After the oil has completely drained out install the drain plug with the gasket Torque Engine Oil Drain Plugs 34 3 5 kgf m 25 ft Ib NOTICE To avoid engine damage do not fill the engine oil above the full level If the oil level in the cylinder head cover gets too high because of filling too fast oil may over flow from the filler opening and or may flow through the crankcase breather hose into the inlet manifold Oil in the inlet manifold may flow into the combustion chambers and cause hydraulic lock resulting in severe engine damage e Remove the oil filler cap and pull the dipstick out a little about 5 cm 2 in to allow the air in the crankcase to escape e Slowly and evenly fill the engine with a good quality oil as specified in the table e Check the oil level Engine Oil Grade API CF or CF 4 Viscosity SAE 10W 40 Capacity 3 0L 3 2 US dt When filter is not removed 3 3 L 3 5 US qt When filter is removed Oil Level Between F and L marks on dipstick NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric
263. l will help seal com pression as it does during normal running e Stop the engine remove the glow plugs and attach a compression gauge A firmly into the one glow plug hole Special Tool Compression Gauge Adapter B 57001 E E M 1431 1 e Wrap a tape around the glow plug lead black white end to insulate e Disconnect the fuel cut solenoid lead connector C e Using the starter motor turn the engine over until the com pression gauge stops rising this is the highest compres sion reading obtainable Cylinder Compression Standard 3 330 kPa 34 0 483 psi at 300 r min rpm Service Limit 2 990 kPa 30 5 kgf cm7 434 psi at 300 r min rpm e Repeat the measurement for the other cylinders OThe following table should be consulted if the obtainable compression reading is not within the spe cific range Remedy Action Cylinder compression is Carbon accumulation on piston Remove the carbon deposits and higher than standard and cylinder head and in replace damaged parts combustion chamber possibly due to damaged valve stem oil seal and or damaged piston oil rings Incorrect cylinder head gasket Replace with a gasket of the proper thickness thickness Cylinder compression is lower Gas leakage around cylinder damaged gasket and than service limit head check cylinder head warp Repair if possible Inspect the cylinder and liner and repl
264. lace the radiator Radiator Cleaning e Refer to the Radiator Cleaning in the Periodic Mainte nance chapter Radiator Cap Inspection e Check the condition of the radiator cap valve seals A and valve spring B x If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leakage e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge pointer must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge pointer flicking downward relief valve must open within the specified range Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 13 18 psi If the cap cannot hold the specified pressure or if it holds too much pressure replace the cap A ANS NS 5606 NS ANN NN WS f 7 6007010451 6007001851 COOLING SYSTEM 4 13 Thermostat Thermostat Removal e ilt up the cargo bed e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Coolant Temperature Switch Lead Connector A Thermostat Housing Cap Bolts B Thermostat Housing Cap C e Remove Locating Screw A Thermostat B Thermostat Installation
265. late models and KAF950GB NOTICE If dirt gets into the torque converter excessive wear and loss of driving power may result e Remove Air Cleaner Housing Bolts A Washers and Nuts Air Cleaner Housing B C KAF950G9 and KAF950GA HA early models D KAF950GA HA late models and KAF950GB IF08009BS1 e After removing the housing stuff pieces of lint free clean cloth into the torque converter cover duct to keep dirt out of the torque converter NOTICE If dirt gets into the torque converter excessive wear and loss of driving power may result CONVERTER SYSTEM 6 9 Air Cleaner Air Cleaner Housing Installation e Install Air Cleaner Housing A Bracket Bolt B Washer C Damper D The shorter side faces lower side Collar E Nut F For KAF950G9 and KAF950GA HA Early Models e Tighten 17208003851 Torque Air Cleaner Housing Mounting Bolts 20 N m 2 0 15 ft Ib For KAF950GA HA Late Models and KAF950GB e Tighten Torque Air Cleaner Housing Mounting Bolts 16 1 6 12 16 e Install the clamps A at about 3mm 0 12 in B from the end of air ducts e Install the clamp C into the bare position from the end of air duct Air Cleaner Element Removal e ilt up the cargo bed For KAF950G9 and KAF950GA HA Early Models e Remove Wingbolts A Cap B 6 10 CONVERTER SYSTEM Air Cleaner For KAF950GA HA Late Models and KAF950GB e Remove Clamps
266. lb 12 24 FINAL DRIVE Bevel Gear Case e Apply grease to the oil seal lips A e Tighten Torque Bevel Gear Case Holder Nuts 25 N m 2 5 18 ft Ib Drive Bevel Gear Removal e Remove the hi low gear case see Hi Low Gear and Shift Mechanism Removal in the Transmission chapter e Hold the transmission gear holder A in a vise Special Tool Transmission Gear Holder 57001 1676 1105016881 e Set the hi low gear case A onto the gear holder e Remove the drive gear nut B e Remove Drive Gear A Drive Gear Shim s B Drive Gear Shaft C Drive Bevel Gear Installation e Check and adjust the bevel gear backlash and tooth con tact when any of the backlash related parts are replaced see Bevel Gear Adjustment e Apply molybdenum disulfide oil solution to the seating sur face of the drive gear nut e Tighten Torque Drive Gear Nut 118 12 0 kgf m 87 0 1 Bevel Gear Case Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load the backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged When replacing any one of the backlash related parts be sure to check and adjust the backlash and tooth contact First adjust the backlash and then tooth contact by replac ing shims These two adjustments are of critical importance and must be carried out in the correc
267. le and set the transmission shift lever A in the correct position as follows e The gap B between the shift lever and panel is approxi mate 1 5 mm 0 06 in OWhen the outer cable moving forward the shift lever moves left side OWhen the outer cable moving rearward the shift lever moves right side e Tighten the hi low shift cable adjuster nuts e oosen the transmission shift cable adjuster nuts A and B e Adjust the transmission shift cable and set the transmis sion shift lever A in the correct position as follows OWhen the shift lever moving to right and left the gaps between B and C are same OWhen the outer cable moving forward the shift lever moves upward OWhen the outer cable moving rearward the shift lever moves downward e Tighten the transmission shift cable adjuster nuts TRANSMISSION 10 17 106011951 1007011951 106011551 10 18 TRANSMISSION Transmission and Shift Mechanism Transmission Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely within the cable housing x If the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable Transmission Removal e Remove Transmission Case see Transmission Case Removal Hi Low Shift Gear see Hi Low Gear and Shift Mecha nism Removal opeedometer Gear see 2WD AWD Shift Mechanism Removal e Split the transmission case see Transmission Case
268. lief Valve Plunger A Relief Valve Spring B Washer C and Relief Valve Bolt D e Tighten Torque Relief Valve Bolt 39 4 0 kgf m 29 ft Ib Relief Valve Inspection e Visually inspect the relief valve spring A and plunger B If any nicks or burrs are found during the above inspec tion replace the parts e Measure the relief valve spring free length xlf the spring is shorter than the standard replace the pd Relief Valve Spring Free Length spring Standard 34 5 36 5 mm 1 358 1 437 in 1605002BS1 C 7 12 ENGINE LUBRICATION SYSTEM Pressure Measurement Oil Pressure Measurement e Remove the oil pressure switch see Oil Pressure Switch Removal e Attach the adapter A and gauge B to the hole Special Tools Oil Pressure Gauge 10kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Install the removed parts see appropriate chapters e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge Oil Pressure Standard 196 490 kPa 2 0 5 0 kgf cm 28 T1 psi at 3 000 r min rpm oil temperature 55 65 C 131 149 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapter is removed e Install the oil pressure switch see Oil Pressure Switc
269. linder Mounting Nuts 65 in Ib Reservoir Clamp Bolt 54 in Ib Suspension Damper Bracket Mounting Nuts o9 6 0 44 R S Front Suspension Arm Joint Nuts 78 8 0 58 Front Suspension Arm Pivot Bolts 98 10 0 72 3 Leaf Spring Mounting Bolts Front 98 10 0 72 3 Leaf Spring Mounting Nuts Rear 59 6 0 44 Rear Shock Absorber Mounting Nuts 59 6 0 44 R Strut Clamp Nuts 98 10 0 72 3 Strut Locknuts 49 5 0 36 Strut Mounting Locknuts 44 4 5 32 R Tie Rod End Nuts 34 3 5 25 Steering EPS Unit Mounting Bolts 20 2 0 15 Rack Guide Spring Cap Locknut 39 4 0 29 Steering Gear Assembly Bracket Bolts 52 5 9 38 Steering Wheel Mounting Nut 52 5 9 38 Strut Clamp Nuts 98 10 0 72 3 Tie Rod End Locknuts 44 4 5 32 Tie Rod End Nuts 34 3 5 25 Universal Joint Clamp Bolts 20 2 0 15 Frame Battery Holder Mounting Nuts 17 1 7 13 Center Bar Mounting Bolts 64 6 5 4T Front Bar Mounting Bolts Lower 98 10 0 72 3 Front Bar Mounting Bolts Upper 44 4 5 32 Front Seat Bar Mounting Bolts 64 6 5 4T Hood Latch Lever Mounting Bolts 37 3 8 27 L PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Rear Bar Mounting Bolts Lower 64 6 5 47 Rear Bar Mounting Bolts Upper 44 4 5 32 Rear Bar Mounting Nuts Middle 44 4 5 32 Rear End Subframe Mounting Nuts 44 4 5 32 ocreen Fixing Lever Screws 4 4 0 45 39 in Ib Seat Buckle Mounting Bolts 34 3 5 25 Seat Belt Mounting Bolts 34 3 5 25 Stay Rod Rear 88 9 0 65 Tail Gate Fixing Lever Screws 4 4 0 45 39 in Ib T
270. lternator Adjusting Bracket Bolts 20 2 0 kgf m 15 ft Ib Alternator Mounting Bolt 39 N m 4 0 kgf m 29 ft Ib Alternator Disassembly e Remove Terminal Nut A Insulator B End Cover Bolts C End Cover D e Remove Brush Holder A Regulator B Rectifier Screws C 17 34 ELECTRICAL SYSTEM Alternator e Straighten the stator coil wires A e Remove the rectifier B e Use the following loosen the pulley locknut A socket Wrench B Special Tool 57001 1236 Deep Socket Wrench C Special Tool Socket Wrench Hex 22 57001 1236 e Remove Pulley Locknut Pulley D e Remove the collar A e Remove Housing Cover Mounting Bolts A and Nuts B Housing Cover C e Remove Rotor A Alternator Housing B ELECTRICAL SYSTEM 17 35 Alternator e Remove Bearing Holder A Ball Bearing B OTo remove the ball bearing A use a suitable puller Alternator Assembly e Press the bearing and bearing holder onto the rotor shaft e Straighten the stator coil wires e Install Housing Cover A Housing Cover Mounting Bolts B and Nuts C e Install the rectifier A e Bend the stator coil wire ends B around the screw holes e Tighten the rectifier screws e Install Regulator Brush Holder End Cover Insulator Terminal Nut 17 36 ELECTRICAL SYSTEM Alternator e Install Collar Pulley A e Use the following tighten the locknut Socket Wrench B Special Too
271. lternator Output Amperage load Standard 20 A or more x If the readings are not within the specified range check the alternator 1009006851 Alternator Stator Coil Inspection e Connect the hand tester x 1 O range between the coil wires and read the tester Special Tool Hand Tester 57001 1394 x If the tester does not read as specified replace the alter nator frame Stator Coil Resistance 0 2 O or less e Using the highest hand tester range measure the resis tance between the stator coil core and each of the coil windings x If there is any reading at all the stator coil winding has short and the alternator housing must be replaced Rotor Coil Inspection e Connect the hand tester x 1 O range between the slip rings A and read the tester Special Tool Hand Tester 57001 1394 x If the tester does not read as specified replace the rotor B Rotor Coil Resistance 2 8 3 0 Q e Using the highest tester range measure the resistance between the rotor shaft and each of the slip rings x If there is any reading at all the rotor coil has a short and must be replaced Slip Ring Cleaning e Visually inspect the slip ring for dirt or pitting necessary smooth the slip ring with No 300 No 500 emery cloth Slip Ring Diameter e Measure the diameter of the slip rings x If the measurement is less than the service limit replace the rotor A Slip Ring Diameter Standard 14 4 m
272. m 0 57 in Service Limit 14 0 mm 0 55 in Carbon Brush Length e Measure the length A that both carbon brushes that stick out of the holder If either one is worn down to less than the service limit replace it Carbon Brush Length Projected Portion Standard 10 5 mm 0 41 in Service Limit 8 4 mm 0 33 in ELECTRICAL SYSTEM 17 37 1009007851 1009008851 17 38 ELECTRICAL SYSTEM Alternator Rectifier Inspection e Set the hand tester to the 1 kO range e Zero the hand tester and connect it to each terminal to check the resistance in both directions OThe resistance should be low in one direction and more than ten times as much in the other direction If the rec tifier A shows low or high in both directions the rectifier is defective and the rectifier must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale NOTICE If a megger or a meter with a large capacity battery is used the rectifier will be damaged Regulator Inspection e Set the hand tester to the 1 kO range Special Tool Hand Tester 57001 1394 e Check the resistance between F A and B B terminals in both directions OThe resistance should be low in one direction and more than ten times as much in the other direction x If the reading shows low or high in both directions the reg
273. m 13 e Bleed the brake line after master cylinder installation e Adjust the brake pedal play see Brake Pedal Play Inspec tion in the Periodic Maintenance chapter e Check that the brake line has proper fluid pressure and no fluid leakage Master Cylinder Disassembly Assembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter Brake Pedal and Master Cylinder Master Cylinder Inspection e Disassemble the master cylinder see Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter e Check that there are no scratches rust or pitting on the inside of the cylinder A and on the outside of the pistons B x If the cylinder or piston shows any damage replace them e Inspect the primary cups C and secondary cups D If a cup is worn damaged softened rotted or swollen replace it x If fluid leakage is noted at the brake push rod sec ondary cup of the rear piston should be replaced e Check the dust cover E for damage x If it is damaged replace it e Check that the relief and supply ports are not plugged x If the small relief port becomes plugged the brake shoes will drag on the drum Blow the ports clean with com pressed air e Check the piston return springs H for any damage x If the spring is damaged replace it BRAKES 13 11 0 0 1405000832 1
274. m disulfide grease thinly in the area C e Install the driven pulley D e Install the stepped collar A on the pulley as shown in the figure Bolt Head B IF07019BS1 e Apply a non permanent locking agent to the threads of the driven pulley bolt e Using a flywheel amp pulley holder A tighten the driven pulley bolt B Special Tool Flywheel amp Pulley Holder 57001 1605 Torque Driven Pulley Bolt 93 9 5 69 e Install the removed parts see appropriate chapters ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents E XDIOGEG VIEW M 7 2 7 4 Special Tools and SSAA se eben nb tin Das erii ou adi e b vue te 7 5 PIOW alt Pe tr eat v uote mca qa tss Unam peers um quus 7 6 Engine Oll and OIl IE e beso imo m eq e bus 7 7 Oll Eevel OS CHO Ds 7 7 Engine Oil and or Oil Filter 7 8 el Rer ROMO Vd 7 8 7 8 Ee SUA SM ten SET R MUS 7 9 Oil Pan and Oil Strainer Removal naan 7 9 Oil Pan and Oil Strainer Installation ui 7 9 Oll
275. mm 0 354 0 358 in Service Limit 9 2 mm 0 362 in Differential Gear Removal e Split the transmission gear case see Transmission Gear Case Splitting e Remove the differential gear A e Remove Differential Gear Housing Bolts A Final Gear B e Remove Housing Cover A Dowel Pin B Side Gear C Spacer D e Remove Dowel Pins A Retaining Pin B Pinion Gear Shaft C Pinion Gears D Spacers Side Gear E Spacer 10 32 TRANSMISSION Differential Gears and Shift Mechanism Differential Gear Installation e Apply transmission oil to the following parts Side Gears Pinion Gears e Apply a non permanent locking agent to the threads of the differential gear housing bolts and tighten them Torque Differential Gear Housing Bolts 57 5 8 kgf m 42 ft lb x If the backlash of the differential gears cannot keep re place the spacers A to thinner spacers Spacers 1 2 mm 0 047 in 92200 0021 1 0 mm 0 039 in 92200 1044 NOTE OUse the spacers of the same thickness as a Set ODo not use the spacers of 1 2 mm 0 047 in and 1 0 mm 0 039 in thickness at the same time Differential Gear Inspection e Visually inspect the differential gears A Replace the gears as a set if either gear is damaged 1J08009BS1 Bearings and Oil Seal Bearing Replacement e Using a press a puller the oil seal amp bearing remover or the bearing driver set remove the bearings
276. mm 49048 1095 0 315 in e Check that the movable sheave A moves smoothly after the shoe side clearance adjustment OThe movable sheave must move freely towards the fixed sheave B x If the movable sheave does not move smoothly readjust the shoe side clearance IF06024BS1 CONVERTER SYSTEM 6 21 Drive Pulley Drive Pulley Assembly e Replace the ramp weight nuts B with new ones e Install the ramp weight A as shown in the figure e Tighten Torque Ramp Weight Nuts 6 9 0 70 kgf m 61 in lb e Check that the ramp weights swing smoothly 1 068016 e Hold fixed sheave A with the drive pulley holders B in a vise Special Tools Drive amp Driven Pulley Holder 57001 1412 Drive amp Driven Pulley Holder 57001 1473 1706012851 e Clean the threads of the fixed sheave and spider e Install Movable Sheave Spider A and Shoes B OAlign the arrow C on the spider with the arrow D on the movable sheave Olnsert the shoes so that the rubber side faces inward e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1549 e Turn the wrench for tightening Torque Spider 275 28 0 kgf m 203 ft Ib e Put the spring A in the groove of the spider e Align the arrows B on the drive pulley cover and spider e Install Dowel Pins C Drive Pulley Cover D e Tighten Torque Drive Pulley Cover Bolts 13
277. moval e oosen the clamp A and separate the air duct B from the cover CONVERTER SYSTEM 6 11 6 12 CONVERTER SYSTEM Torque Converter e Remove Inner Cover Bolts A and Collars Clamps B Nut C e Avoid the bracket A and remove the inner cover B up ward Torque Converter Inner Cover Installation e Replace the nut E with a new one e Install Inner Cover A Clamps B Inner Cover Bolts 30 mm 1 18 in C Inner Cover Bolt L 35 mm 1 38 in D Nut Collars F When installing the trim add the glue to the place be tween bolt hole and bolt hole e Tighten Torque Inner Cover Bolts 4 4 N m 0 45 kgf m 39 in Ib Inner Cover Nut 8 8 N m 0 90 kgf m 78 in Ib e Install the drive pulley see Drive Pulley Installation e Install the removed parts see appropriate chapters Torque Converter Case Removal e Remove Drive Pulley see Drive Pulley Removal Driven Pulley see Driven Pulley Removal Damper Bracket Nuts A Loosen Torque Converter e Hold the left part of the rear axle bracket with a jack A e Remove Leaf Spring Mounting Nuts B Leaf Spring Rods C e oosen the clamp A and remove the air duct B from the torque converter case e Remove Converter Case Bolts A Converter Case Nut B and Washer Torque Converter Case C e Place an oil pan beneath the drive shaft of the transmis sion case OAvoid the brake hose bracket A and remove the torque
278. n Belt In spection in the Periodic Maintenance chapter COOLING SYSTEM 4 9 Water Pump Water Pump Inspection e Check the drainage outlet passage at the top A and bot tom B of the water pump body for coolant leakage xlIf the mechanical seal is damaged the coolant leaks through the seal and drains through the passages Re place the water pump unit e Remove the water pump pulley A and check it x If the pulley is bent or damaged replace the pulley e Check the water pump bearings by rotating pulley flange A by hand OMake sure pulley rotates smoothly If the water pump shows evidence of the bearings are rough replace the water pump unit 4 10 COOLING SYSTEM Radiator and Radiator Fan Radiator Removal WARNING A spinning radiator fan can cause serious injury The radiator fan is connected directly to the battery and may start even if the main switch is off Do not touch the radiator fan until it has been disconnected from the battery e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Front Cover see Front Cover Removal in the Frame chapter Radiator Fan Lead Connector A e Remove the water hoses e urn over the rubber cover A e Disconnect the radiator fan switch lead connectors B e Remove Radiator Mounting Bolts A Radiator with Screen B NOTICE Do not touch the radiator core This could damage the radiator fins
279. n in the Periodic Maintenance chap ter Wheel Cylinder Removal Installation e Refer to the Brake Wheel Cylinder Assembly Replace ment in the Periodic Maintenance chapter Wheel Cylinder Assembly e Before assembly clean all parts including the wheel cylin der with brake fluid or alcohol and apply brake fluid to the removed parts and the inner wall of the cylinder NOTICE Use only brake fluid isopropyl alcohol or ethyl al cohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline motor oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventu ally deteriorate the rubber used in the brake Brake Panel Assemblies Wheel Cylinder Inspection e Remove the wheel cylinder see Brake Wheel Cylinder Assembly Replacement in the Periodic Maintenance chapter e Disassemble the wheel cylinder e Check that there are no scratches rust or pitting on the inside of the cylinder and on the outside of the piston x If the cylinder or piston shows any damage replace the cylinder e Inspect the cups If a cup is worn damaged softened rotted or swollen replace the cylinder x If fluid leakage is noted at the dust seals the cylinder should be replaced to renew the cup e Check the dust seals for damage x If they are damaged replace the cylinder e Check the spring for any damage x
280. n nozzle properly Good Malfunctioning injection pump 10120068 FUEL SYSTEM 3 29 Air Cleaner A clogged engine air cleaner restricts the engine s air in let increasing fuel consumption reduction engine power NOTICE A clogged air cleaner may allow dirt and dust to en ter the engine causing excessive wear and possible engine damage The engine air filter restriction gauge A shows whether the air cleaner is clogged Whenever the red band shows in the gauge window B the air cleaner element should be cleaned Air Cleaner Element Cleaning e Unlock the clamps A e Remove the air cleaner cover B e Remove the element A e Clean the element by tapping gently with the handle end of a screwdriver x If the element is very dirty or damaged replace the ele ment e Carefully clean out the air cleaner cover e Install the cover and lock the clamps OFace the TOP mark A upward 3 30 FUEL SYSTEM Air Cleaner e Reset the air filter restriction gauge A OAfter servicing the air cleaner element the restriction gauge should be reset by pushing the button B at the end of the gauge Air Cleaner Housing Removal e Tilt up the seat e Remove Air Ducts A Air Cleaner Housing Mounting Bolts B Air Cleaner Housing C Air Cleaner Housing Installation e Apply sealant to the area A shown in the figure Sealant General Electric RTV100 Black ODo not apply sealant to the inside
281. n the back end of the carrier B and the bottom of the tail gate C is more than 2 mm 0 079 in as shown in the figure left and right OBe sure the clearance A between the plate end B and the tail gate end C is less than 5 mm 0 197 in as shown in the figure left and right FRAME 16 21 16 22 FRAME Front Center and Rear Bars Front Bar Removal e Remove Front Fenders see Front Fender Removal Front Bar Mounting Bolts A and Washers Upper Front Bar Mounting Bolts B Lower Front Bar C Front Bar Installation e lighten Torque Front Bar Mounting Bolts Upper 44 N m 4 5 kgf m 32 ft lb Front Bar Mounting Bolts Lower 98 N m 10 0 72 3 ft lb e Install the front fenders see Front Fender Installation Rear Bar Removal e ilt up the cargo bed e Remove Rear Side Covers see Rear Side Cover Removal Rear Bar Mounting Bolts A and Washers Upper e Remove Air Duct A Rear Bar Mounting Bolts B and Nuts Middle Rear Bar Mounting Bolts C Washers and Nuts Lower e Remove Air Duct A Rear Bar Mounting Bolts B and Nuts Middle Rear Bar Mounting Bolts C Washers and Nuts Lower Rear Bar D FRAME 16 23 Front Center and Rear Bars Rear Bar Installation e Be sure the rubber plates A are in position OPlug one hole B and plug only half about another hole C using the rubber plate e Be sure the rubber dampers A are in position OThe rubber damper rear
282. n the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole STEERING 15 15 1005011 82 HJ07007BS1 15 16 STEERING Steering Gear Assembly e Bend the cotter pin A over the nut B e Check the toe in of the front wheels see Toe in Adjust ment in the Wheels Tires chapter e Be sure to register the EPS neutral position see EPS Neutral Position Registration Steering Gear Preload Adjustment e oosen the locknut A e Tighten the rack guide spring cap B to 12 3 N m 1 25 kgf m 109 in lb of torque e Back off the cap 40 50 e Tighten the locknut while preventing the cap from turning Torque Rack Guide Spring Cap Locknut 39 4 0 kgf m 29 ft lb Pinion C Rack D Rack Guide E Spring F e Be sure to register the EPS neutral position see EPS Neutral Position Registration Tie Rod Length Adjustment e Refer to the Toe in Adjustment in the Wheels Tires chap ter Tie Rod Length A Front B Steering Joint Dust Boot Inspection e Refer to the Steering Joint Dust Boot Inspection in the Periodic Maintenance chapter J04109BS1 Steering Knuckles Steering Knuckle Removal e Remove Front Brake Panel Assembly see Brake Panel Assy Re moval in the Brakes chapter Cotter Pin Tie Rod End Nut A Tie Rod End B from Steering Kn
283. nd front to rear e Remove the front final gear case skid plate see Front Final Gear Case Oil Level Inspection in the Final Drive chapter e Place an oil pan beneath the front final gear case and remove the drain plug A A WARNING Oil on tires can cause loss of traction and an ac cident resulting in serious injury or death When draining or filling the final gear case do not spill oil the tire or rim Clean any oil that may spill with a high flash point solvent 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e After the oil has completely drained out install the drain plug with a new aluminum gasket and tighten it Torque Oil Drain Plug 20 N m 2 0 kgf m 15 ft Ib e Fill the gear case up to the bottom A of filler opening B with the oil specified below Front Final Gear Case Oil Type Hypoid gear oil for LSD Limited Slip Differential gears Viscosity SAE 140 GL 5 SAE 90 GL 6 Capacity 0 4L 0 4 US qt Oil Level Filler opening level NOTE O GL 5 or GL 6 indicate a quality and additive rating e Be sure the O ring A is in place and tighten the filler cap Filler Opening B Torque Oil Filler Cap 29 3 0 kgf m 21 ft Ib e Install the front final gear case skid plate see Front Final Gear Case Oil Level Inspection in the Final Drive chapter Brakes Brake Fluid Level Inspection e With the vehicle on level ground check that the fluid level in the reservoir is be
284. ng Wheel and Main Shaft Assembly Steering Wheel and Steering Shaft Removal KAF950G9 GC HA e Remove the wheel cap together with the horn switch as follows Olnsert a thin driver A into the hole B and unlock the stopper OPry the one side part of the switch with a thin driver for the stopper A is free ORemove the wheel cap B together with the horn switch oo e When removing the horn switch unlock the stoppers A e Remove Self lock Nut A and Spring Washer Steering Wheel B e Cut the bands A e Disconnect the horn switch and connector B 15 8 STEERING Steering Wheel and Main Shaft Assembly e Remove Screws A and Holder Horn Switch Contact B e Remove Front Cargo Compartment see Front Cargo Compart ment Removal in the Frame chapter Universal Joint Clamp Bolt A e Remove Steering Shaft Mounting Bolts Washers Nuts A Steering Shaft B Steering Wheel and Steering Shaft Installation KAF950G9 GC HA e Apply grease to the dust cover lips A e Install the steering shaft A to the upper universal joint B e Install the universal joint clamp bolt C while aligning the notch on the steering shaft with the clamp bolt hole on the upper universal joint and tighten it temporary e Replace the steering shaft mounting nuts F with new ones e Install the steering shaft mounting bolts D washers E and nuts e Tighten the universal joint clamp bolt to the sp
285. nkshaft bearing worn Cooling fan belt loose Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Transmission oil insufficient Final drive noise Bearing worn Gears worn or chipped Metal chips jammed in gear teeth Insufficient lubricant Bevel gears maladjusted 150 clutch friction plate worn LSD clutch spring worn Universal joint damaged Abnormal Frame Noise Shock absorber noise Shock absorber damaged Brake noise Brake linings overworn or worn unevenly APPENDIX 18 33 Drum worn unevenly or scored Brake spring s weak or broken Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Steering wheel hard to turn Steering shaft bearing damaged oteering shaft lubrication inadequate Steering shaft bent Steering gear assembly damaged Tire air pressure too low LSD clutch maladjuste
286. nsmission Oil Change e Refer to the Transmission Oil Change in the Periodic Maintenance chapter Transmission Case Transmission Case Removal e Drain the transmission oil see Transmission Oil Change in the Periodic Maintenance chapter e Remove Cargo Bed see Cargo Bed Removal in the Frame chap ter Propeller Shaft see Propeller Shaft Removal in the Final Drive chapter Torque Converter Case see Torque Converter Case Re moval in the Converter System chapter Rear Drive Shafts and Axles see Rear Drive Shaft and Axle Removal in the Final Drive chapter Muffler see Muffler Removal in the Engine Top End chapter e Remove Neutral Switch Terminal Lead A Speed Sensor Lead Connector B 2WD AWD Shift Cable Lower End C Differential Shift Cable Lower End D e Remove Transmission Shift Cable Lower End Lever A Hi Low Shift Cable Lower End Lever B Bolts C and Collars Injection Pump Cover D e Remove Bolts and Nuts A Engine Mount Stay B TRANSMISSION 10 11 10 12 TRANSMISSION Transmission Case e Remove Bolt A Thick Holder B Thin Holder C opeedometer Cable Lower End D e Remove Transmission Case Mounting Bolts and Nuts A Transmission Case B Transmission Case Installation e Adjust the transmission case mounting position see En gine Installation in the Engine Removal Installation chap ter e Tighten Torque Transmission Case Mounting Nuts 44 4 5 kgf m 32 ft lb
287. nsmission and Shift Mechanism Inspection e Visually inspect the forward gears reverse sprockets gear and shaft bushings A drive chains and shifter x If they are damaged or worn excessively replace them e Replace parts worn beyond the service limit Shift Arm Pin Diameter A Standard 7 95 8 00 mm 0 313 0 315 in Service Limit 7 8 mm 0 307 in Shifter Block Inside Diameter B Standard 8 05 8 10 mm 0 317 0 319 in Service Limit 8 2 mm 0 323 in Shifter Block Outside Diameter C Standard 13 95 14 00 mm 0 549 0 551 in Service Limit 13 8 mm 0 543 in Shifter Groove Width D Standard 14 0 14 2 mm 0 551 0 559 in Service Limit 14 3 mm 0 563 in Drive Chain 20 Link Length B Standard 158 76 159 18 mm 6 250 6 267 in Service Limit 161 1 mm 6 343 in Force A 1st Pin C 2nd Pin D 21th Pin E 0 11020151 TRANSMISSION 10 21 Hi Low Gears and Shift Mechanism Hi Low Shift Cable Installation e Refer to the Transmission and Hi Low Shift Cables Instal lation Hi Low Shift Cable Inspection e With the cable disconnected at both ends the cable should move freely within the cable housing x the cable movement is not free if the cable is frayed or if the housing is kinked replace the cable Hi Low Gear and Shift Mechanism Removal e Remove Bevel Gear Case see Bevel Gear Case Removal in the Final Drive chapter Hi Low Shift Shaft Lever A 2WD A
288. nstalla T 15 55 Speed Sensor Inspection 15 55 EPS ECU Relay Removal Instal 15 56 EPS ECU Relay Inspection 15 56 Diodes Removal Installation 15 56 Diodes Inspection 15 57 EPS Fuse 40 A Removal 15 57 EPS Fuse 7 5 A Removal 15 58 Fuse Installation 15 58 Fuse Inspection 15 58 15 2 STEERING Exploded View STEERING 15 3 Exploded View 6 Unit Mounting Bos 120 15 2 Rack Song 40 9 3 Steering Gear Assembly Bracket Bots 52 53 38 _ 4 8 53 76 TeRodEndlommts 44 4 TieRodEnd 34 78 Universal Joint Ciamp Bots 20 9 KAF950G9 GC HA 10 Apply grease on contact plate G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 STEERING Specifications Mem Standard Steering Wheel Steering Wheel Free Play 0 20 mm 0 0 79 in Service Limit Steering Gear Assembly Tie Rod Length 43 5 mm 1 71 in distance between boot end and locknut STEERING 15 5 Special Tools Outside Circlip Pliers Knuckle Joint Remover 57001 144 57001 1619 ST5701448T 8 5716198 Bearing Driver Set Knuckle Joint Driver 57001 1129 57001 1640 75711298T 875716408 Hand Tester 57001
289. nsufficient first check the front final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case e Be sure the O ring B is in place and tighten the filler cap Torque Filler Cap 29 3 0 kgf m 21 ft Ib e Replace the front final gear case skid plate nuts with new ones and install the skid plate Front Final Gear Case Oil Change e Refer to the Front Final Gear Case Oil Change in the Pe riodic Maintenance chapter 1048126 FINAL DRIVE 12 9 Front Final Gear Case Front Final Gear Case Removal e Drain the front final gear case oil see Front Final Gear Case Oil Change in the Periodic Maintenance chapter e Remove Radiator see Radiator Removal in the Cooling System chapter Propeller Shafts see Propeller Shaft Removal Front Axles see Front Axle Removal Vent Hose A Front Final Gear Case Mounting Bolts and Nuts B Collar C e Remove Front Final Gear Case Bracket Bolts A Front Final Gear Case Bracket B e Remove the front final gear case A upward together with the mounting bolt B Front Final Gear Case Installation e Run the gear case vent hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Replace the gear case mounting nuts with new ones e Tighten Torque Gear Case Bracket Bolts 44 N m 4 5 32 ft Ib Gear Case Mounting Nut
290. nt OWipe off any spilled fuel e Start the engine and check for fuel leakage EX ag fi PAT EL GSO5005BS1 1805002851 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Cleaning NOTICE Clean the radiator screen and the radiator in ac cordance with the Periodic Maintenance Chart In dusty areas they should be cleaned more fre quently than the recommended interval After riding through muddy terrain the radiator screen and the radiator should be cleaned immediately e Remove Front Cover see Front Cover Removal in the Frame chapter Radiator Screen Mounting Bolts A Radiator Screen B e Clean the radiator screen in a bath of tap water and then dry it with compressed air or by shaking it NOTICE When cleaning the radiator with a steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 OK Perpendicular ft B from the radiator core Hold the steam gun perpendicular to the core sur face Run the steam gun following the core fin direction e Install the radiator screen 8007010581 e Tighten Torque Radiator Screen Mounting Bolts 8 8 0 90 kgf m 78 in Ib Radiator Hose and Connection Inspection OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of de
291. o renew the oil seal e Visually inspect the rubber bushings in the upper and or lower mountings of the rear shock absorber x If they are worn cracked hardened or otherwise dam aged replace them with new ones Front Suspension Arms Front Suspension Arm Removal e Remove Front Wheel see Wheel Removal in the Wheels Tires chapter Front Guard see Front Guard Removal in the Frame chapter e Hold the front brake drum and panel assembly in position e Remove the front suspension arm pivot bolts A e Remove Cotter Pin Front Suspension Arm Joint Nut A Front Suspension Arm Joint from Steering Knuckle ORemove the front suspension arm joint from the steering knuckle using a suitable joint remover see Steering Gear Assembly Removal in the Steering chapter e Remove the front suspension arm B Front Suspension Arm Installation e Clean the tapered portion of the front suspension arm joint and the tapered hole of the suspension arm or the tapers will not fit snugly e Apply grease to the sealing surface A of the front sus pension arm joint boot e When the front suspension arm pivot bolts are tightened install the arm joint to the suspension arm to position the arm within its operating angle e Apply a non permanent locking agent to the threads of the front suspension arm pivot bolts e Tighten Torque Front Suspension Arm Pivot Bolts 98 10 0 72 3 ft lb Front Suspension Arm Joint Nut 78
292. o the transmission shift cable C end and install the cable onto the bracket D e up the punch mark A on the shift arm projection B on the transmission case and slit opening in the shift shaft lever C e Tighten Shift Shaft Lever Nut D Shift Shaft Lever Clamp Bolt E e Hold the shift shaft lever A in the neutral position and then pull the outer cable B lightly forward to remove the cable free play NOTE the cable cannot be adjusted move the slit opening in the shift shaft lever one notch to right side of the punch mark on the shift arm e Tighten Transmission Shift Cable Adjuster Nut C Transmission Shift Cable Adjuster Nut D e Install the spring A back onto the shift shaft lever assem bly e Check the shift lever position see Shift Lever Position Inspection Transmission and Shift Mechanism Shift Lever Position Inspection e Start the engine and put the shift lever in NEUTRAL or L LOW position e Move the shift lever A slowly to the direction of the arrow on the figure At this time increase the engine speed slightly e Check the grinding noise at the specified positions B and C x If the position of the grinding noise is far from the specified position adjust the shift lever position see Shift Lever Position Adjustment Shift Lever Position Adjustment e Loosen the hi low shift cable adjuster nuts A and e Adjust the hi low shift cab
293. ocedures Wheels Wheel Nuts Brakes Brake Pedal Pivot Shaft Cotter Pin Master Cylinder Mounting Bolts Master Cylinder Push Rod Joint Cotter Pin Parking Brake Cable Lower End Joint Cotter Pins Parking Brake Lever Assembly Mounting Bolts Suspension Front Suspension Arm Pivot Bolts Leaf Spring Mounting Nuts Rear Shock Absorber Mounting Nuts Strut Clamp Nuts and Cotter Pins Strut Mounting Locknuts Steering Front Suspension Arm Joint Nuts and Cotter Pins Steering Shaft Mounting Bolts and Nuts Steering Wheel Mounting Nut Tie Rod End Locknuts Tie Rod End Nuts and Cotter Pins Universal Joint Clamp Bolts Frame Battery Holder Mounting Nuts Cargo Bed Hook Mounting Bolts Cargo Bed Mounting Pin Snap Pins Front and Rear Bar Mounting Bolts and Nuts Front and Rear Seat Back Mounting Nuts Front and Rear Seat Belt Mounting Bolts Front and Rear Seat Belt Backle Mounting Bolts Front Final Gear Case Skid Plate Mounting Bolts Front Guard Nuts Rear End Subframe Mounting Nuts Seat Bracket Nuts FUEL SYSTEM 3 1 Fuel System Table of Contents EXDIOGEG VIEW c 3 2 DOS CIC QUOS ustedes pne MM M MEER MM OI MEDI tM ILU e 3 8 MrR mmU 3 9 Throttle Pedaliard QabDle c uerit aeo 3 10 Throttle Pedal Play Inspection 3 10 Throttle Pedal
294. od End Nuts Universal Joint Clamp Bolts EPS Unit Mounting Bolts OBefore delivering the vehicle to the customer be sure to erase any service codes which might be stored in the EPS ECU Using the self diagnosis function confirm that the EPS warning indicator light LED lights up This shows that there is no service code in the EPS ECU EPS System Troubleshooting Outline The EPS ECU is equipped with a self diagnosis function When an abnormality in the EPS system occurs the EPS ECU lights the EPS warning indicator light LED A to alert the rider In addition the condition of the problem is stored in the memory of the EPS ECU as service codes and in the self diagnosis mode the service code is indicated by the number of times the EPS warning indicator light LED blinks EPS Electric Power Steering System If due to a malfunction the EPS warning indicator light LED remains lit try to understand the background of the trouble before starting the repair work First ask the rider about the conditions A of the trouble and then start to ex amine the cause B of the trouble Do not rely solely on the self diagnosis function use common sense for example check the connections of the connector If the problem is with the following parts the EPS ECU can not recognize these problem Therefore EPS warning indicator light LED does not light up and service code is not indicated EPS Warning Indicator Light LED EPS EC
295. oded View Camshat Drive Gears 44 _ p 2 Camshaft Retainer Bots 78 080 69mb 73 ComecigRedCapNus 36 37 27 Coolant Dran Pus 25 25 1 ti S Crankshaft Main Bearing Cap Bots 5 eo 44 _ 6 CrankshaftPuleyBot 100 723 EO 7 Paess 40 29 8 Flywheel Mounting Bots 44 45 32 LS 79 Fuel injection Pump Drive GearNut 64 65 4 aof 25 25 18 14 12 oi Pump Drive Gears 20 20 15 _ 13 Oi Seal Retainer Bos 54 055 14 Timing Gear Gase Bos 78 080 15 Timing Gear Case Gover Bots 78 oso EO Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement Parts 5 Follow the specified tightening sequence 9 4 CRANKSHAFT CRANKCASE Specifications Standard Timing Gear Case Timing Gear Backlash 0 2 mm 0 008 in Idle Gear Inside Diameter 34 17 mm 1 3453 in Idle Gear Shaft Outside Diameter 33 91 mm 1 3350 in Camshaft Cam Height Inlet 30 065 30 135 mm 29 965 mm 1 1837 1 1864 in 1 1797 in Exhaust 30 065 30 135 mm 29 965 mm 1 1837 1 1864 in 1 1797 in Camshaft Journal Diameter Right Side 35 959 35 975 mm 35 89 mm 1 4157 1 4163 in 1 413 in Center 35 910 35 9
296. of ambi ent temperature NOTICE Do not check the level through the coolant filler by removing the radiator cap If the cap is removed the coolant will flow out from the reserve tank e Tilt up the front cargo hood e Check the coolant level in the reserve tank A with the vehicle parked on a level surface x If the coolant level is lower than the L Low level line C remove the reserve tank cap B then add coolant to the F Full level line D NOTICE For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum engine parts In an emergency soft water be added But the diluted coolant must be returned to the cor rect mixture ratio within a few days If coolant must be added often or the reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Reserve Tank Removal e Tilt up the front cargo hood e Remove Quick Rivets A Tapping Screw B and Collar Partition C COOLING SYSTEM 4 7 Coolant e Remove the coolant reserve tank mounting bolts A e Remove the cap and poor the coolant into a container e Remove Reserve T
297. on in the Electrical oystem chapter x If the speed sensor is normal check the wiring for conti nuity Refer to the next wiring diagram Speed Sensor Circuit 1 EPS ECU 5 Battery 12 V 52 Ah 2 Speed Sensor 6 Main Fuse 30 A 3 Oil Pressure Warning Indicator Light 7 Fuse Box 2 4 Main Switch 8 Oil Pressure Switch STEERING 15 55 ER at w e 5 N 1008028812 15 56 STEERING EPS Electric Power Steering System EPS ECU Relay Removal Installation NOTICE Never drop the relay especially on a hard surface Such a shock to the relay can damage it e Tilt up the seat e Remove the EPS ECU relay A BK Y W Y BR W BL from the tongue and disconnect the connector e Installation is the reverse of removal EPS ECU Relay Inspection e Remove EPS ECU Relay see EPS ECU Relay Removal Instal lation e Connect the hand tester A and a 12 V battery B to the relay C as shown Special Tool Hand Tester 57001 1394 Testing Relay Hand Tester Range x 1 Criteria When battery is connected 0 O When battery is disconnected Relay Coil Terminals 1 and 2 dL Relay Switch Terminals 3 and 4 If the relay does not work as specified replace the relay Diodes Removal Installation e ilt up the front seat and remove the diodes A e Installation is the reverse of removal 1008042851 EPS Electric Power Steering S
298. on the front tires are at the rear side and at the same level as the axle e Measure the distance between the scribed lines e Subtract the measurement of the front from the measure ment of the rear to get the toe in Toe in of Front Wheels Standard 0 20 mm 0 0 79 in at 1G x If the toe in is not the specified value perform the follow ing procedure e oosen the locknuts A on each tie rod and turn the ad justing rods B the same number of turns and the same direction on both sides to achieve the specified toe in WHEELS TIRES 11 5 IK04000B 5 11 6 WHEELS TIRES Wheel Alignment NOTE OThe toe in will be near the specified range if the length of the tie rod distance between the dust boot end A of steering gear assembly and the locknut B is 43 5 mm 1 71 in C on both the left and right tie rods e Tighten Torque Tie Rod End Locknuts 44 N m 4 5 kgf m 32 ft Ib e Check the toe in again e Test drive the vehicle Wheels Rims Wheel Removal e oosen the wheel nuts A ODo not remove the wheel nuts e Lift the wheel s off the ground e Remove Wheel Nuts Wheel s Wheel Installation e Position the wheel so that the valve stem A is toward the outside of the vehicle e Tighten Torque Wheel Nuts 137 N m 14 0 kgf m 101 ft Ib OTighten the wheel nuts in a criss cross pattern Wheel Rim Inspection e Examine both sides of the rim for dents A x the rim is dented
299. onnecting rod on a surface plate Any distortion will be evident by a rocking motion If a 0 05 mm 0 0020 in thickness gauge can be inserted at the connecting rod small end replace the connecting rod Connecting Rod Thrust Faces Service Limit Distortion 0 05 mm 0 0020 in Crankshaft Inspection e Visually inspect the crankshaft main journals and crankpins for grooves or signs of scoring x If any damage is found the crankshaft must be re ground or replaced 9 22 CRANKSHAFT CRANKCASE Crankshaft and Connecting Rods e Check the crankshaft main journals and crankpins for wear and taper Crankshaft Main Journal Diameter A Standard 41 976 42 000 mm 1 6526 1 6535 in Crankshaft Crankpin Diameter B Standard 36 976 37 000 mm 1 4557 1 4567 in Crankshaft Out of Round and Taper Service Limit 0 02 mm 0 00068 in x If the crankshaft main journals are not within specification the crankshaft may be re ground and undersize bearing inserts installed Undersize Crankshaft Main Bearing Inserts 0 25 mm 0 0098 in Undersize e The final finishing dimensions should be as shown in the table Finishing Dimensional Specifications 41 726 41 750 mm 1 6428 1 6437 in B 36 726 36 750 mm 1 4459 1 4468 in R 2 5 mm 0 0984 in D R2 1 mm 0 0827 in e Measure the crankshaft runout at 3 main journal If the measurement exceeds the service limit replace the crankshaft C
300. op Bar Mounting Bolts 44 4 5 32 Electrical System Alternator Adjusting Bracket Bolts 20 2 0 15 Alternator Mounting Bolt 39 4 0 29 Alternator Pulley Locknut 11 1 1 97 in Ib Battery Holder Mounting Nuts 17 13 Connecting Plate Nuts 1 2 0 12 11 in Ib Coolant Temperature Switch 27 2 8 20 L Glow Plugs 17 1 7 13 Neutral Switch 15 1 5 11 Oil Pressure Switch 14 1 4 10 SS Radiator Fan Switch KAF950GB 23 2 3 17 Radiator Fan Switch KAF950G9 GA HA 25 2 5 18 Speed Sensor Bolt 8 8 0 90 78 in lb Starter Motor End Cover Screws 1 5 0 15 13 in lb Starter Motor Mounting Bolts 39 4 0 29 Starter Motor Through Bolts 9 3 0 95 82 in lb The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners of Engine Parts Threads Diameter mm bolt head fib _ Mark of Torque 18 22 1 8 22 13 16 10 20 24 2 0 24 14 17 10 39 44 4 0 4 5 29 33 8 4r 1 14 10 14 87 120iib 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Basic Torque for General Fasteners of Frame Parts Threads Diameter 0 35 0 50 30 43 15 0 60 0 80 52 69 in lb 19 26 1 4 1 9 10 14 33 45 PERIODIC MAINTENANCE 2 11 Specifications tem Standard Fuel System Th
301. or mal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark ar rester e Remove the drain plug A from the muffler B e Apply the parking brake e n an open area away from combustible materials start the engine with the gear shift lever in the N neutral po sition e Raise and lower engine speed while tapping on the muf fler with a rubber mallet until the carbon particles are purged from the muffler DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area e Stop the engine e Install the drain plug Converter System Drive Belt Inspection e Remove the drive belt see Drive Belt Removal in the Converter System chapter e Measure the width A of the belt x If any measurements exceed the service limit replace the POLS GOH m EAS AA belt Belt Width Standard 34 1 mm 1 34 in Service Limit 32 6 mm 1 28 in 05000851 e Check the belt for wear cracks breaks or peeling x If necessary replace the belt with a new one Belt A Crack B Broken C NOTE OWhenever the belt is replaced inspect the drive and the driven pulleys 1 05001 81 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures
302. or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 08020128 5 08020138 5 08020148 5 08020158 5 68020158 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 Do not remove pressed oil or grease seals unless removal 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 installing the seal Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation GENERAL INFORMATION 1 5 YN mS 68020175 5 08020188 5 08020198 5 6802046851 GB02
303. or Inspection Service Code 61 e Remove the front cargo compartment see Front Cargo Compartment in the Frame chapter e Turn the main switch OFF e Disconnect the EPS motor connector A B KAF950G9 GC HA C KAF950GD 5 1 INN NNN E 1008018 81 STEERING 15 45 EPS Electric Power Steering System e Set the hand tester to the x 10 range and connect it to the EPS motor connector A Special Tool Hand Tester 57001 1394 B KAF950G9 GC HA C KAF950GD e Measure the EPS motor resistance EPS Motor Resistance Inspection Connections Lead D BK Lead E Standard Any Reading Resistance reference KAF950G9 0 15 0 19 at 20 C 68 F Standard Any Reading Resistance reference KAF950GD 0 13 at 20 C 68 F x If the reading is infinity replace the EPS unit see EPS Unit Removal Installation x If the reading is not infinity gt disconnect the EPS ECU connectors and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector A EPS Motor Connector B R Lead Terminal C Dr 4 BK Lead Terminal D x If the wiring is good check the power supply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation
304. orn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other Engine oil viscosity too high Front final gear case oil viscosity too high Drive train trouble Brake dragging Poor Running or No Power at High Speed Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel line clogged Fuel injection pump trouble Compression low Fuel injection nozzle loose Glow plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect 18 32 APPENDIX Troubleshooting Guide Miscellaneous Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Front final gear case oil viscosity too high Drive train trouble Overheating Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Compression high Carbon built up in combustion chamber Engine load faulty Engine oil l
305. orn past the service limit replace the friction plates and steel plates as a set Outside Friction Plate A Inside Friction Plate B Outside Friction Plate Thickness Standard 2 3 2 4 mm 0 091 0 094 in Service Limit 2 1 mm 0 083 in Inside Friction Plate Thickness Standard 2 7 2 8 mm 0 106 0 110 in Service Limit 2 4 mm 0 094 in Pinion Gear Unit Disassembly e Remove the pinion gear unit see Front Final Gear Case Disassembly e Pry open the toothed washer tab A on the pinion gear slotted nut B e Unscrew the pinion gear slotted nut Special Tools Pinion Gear Holder A 57001 1281 Socket Wrench B 57001 1283 e Remove the slotted nut flat washer and toothed washer e Pull the pinion gear out of the bearing housing e Remove the tapered roller bearing inner race as neces sary Special Tool Bearing Puller 57001 135 Pinion Gear Unit Assembly e he pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be re placed as a set e Visually inspect the tapered roller bearings for abrasion color change or other damage x If there is any doubt as to the condition of a bearing re place the bearing housing and the bearings as a set e Be sure to check and adjust the pinion gear bearing preload and the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment OWhen
306. ows through a resistor to the solenoid reducing the current slightly but maintaining enough energy to hold the valve open Turning the main switch to the OFF position shuts off the current to the solenoid With no current to hold the valve the spring forces the valve to close the fill port thus shutting off the fuel supply and the engine Fuel Cut Solenoid Inspection e When the main switch is turned ON check that the fuel cut solenoid makes a clicking sound operating sound x If the fuel injection pump does not click replace it or con sult a reliable fuel injection pump repair shop ex Denso Service Station Fuel Cut Solenoid Circuit Main Switch Battery Main Fuse 30 A Preheating Timer Fuse 5 A Fuse Box 2 Fuel Cut Solenoid Fuel Injection Pump NOOR WD ud START or ON 1918002812 C ELECTRICAL SYSTEM 17 51 Radiator Fan Radiator Fan Circuit Inspection e Remove the front cargo compartment see Front Cargo Compartment Removal in the Frame chapter e Disconnect the leads from the radiator fan switch e Using an auxiliary lead A connect the radiator fan switch leads x If the radiator fan rotates inspect the radiator fan switch x If the radiator fan does not rotate inspect the following Wiring and Connectors Radiator Fan Breaker see Radiator Fan Breaker In spection Radiator Fan Motor see Radiator Fan Motor Inspection Radiator Fan Relay see Radiator Fan Relay Inspection
307. p Pliers Hexagon Wrench Hex 32 57001 144 57001 1194 875701445 ST5711948T Oil Seal amp Bearing Remover Liquid Gasket TB1105B 57001 1058 92104 002 5757105857 ST8200028T Bearing Driver Set 57001 1129 875711295 10 10 TRANSMISSION Transmission Oil NOTICE Vehicle operation with insufficient deteriorated or contaminated transmission oil will cause acceler ated wear and may result in transmission failure Transmission Oil Level Inspection NOTE Olf the vehicle has just been used wait several minutes for all the oil to settle down e Park the vehicle on level ground and tilt up the cargo bed e Unscrew the oil filler cap A wipe its dipstick B dry and insert it into the filler opening but DO NOT SCREW IT IN e Pull out the dipstick and check the oil level The oil level should be between the upper H and lower L level lines C x If the oil level is too high remove the excess oil using a syringe or some other suitable device through the oil filler opening x If the oil level is too low add the necessary amount of oil through the oil filler opening Use the same type and make of oil that is already in the transmission NOTE Olf the transmission oil type and make are unknown use any brand of the specified oil to top up the level in pref erence to running the transmission with the oil level low Then at your earliest convenience change the oil com pletely Tra
308. pecification check seat width against specification Results Machinist s dye on seat 60 Grind 60 Cutter reduce seat width to specification Tool Purpose Valve Lapper Grinding Compound perfectly match valve and valve seat area check valve head for damage FINISHED GE15143B F Valves Valve Spring Free Length e Measure the valve spring free length x If the free length is less than the service limit replace the valve spring A with a new one Valve Spring Free Length Standard 30 7 mm 1 2087 in Service Limit 29 7 mm 1 1693 in Valve Head Thickness e Measure the thickness A of the valve head x If the valve head thickness is less than the service limit replace the valve with a new one Valve Head Thickness Standard 1 2 mm 0 0472 in Service Limit 1 0 mm 0 0394 in Valve Stem Diameter e Measure the diameter of the valve stem at specified dis tance from end of the valve A as shown in the figure 35 mm 1 38 in B any single measurement is less than the service limit replace the valve with a new one Valve Stem Diameter Standard Inlet 5 945 5 960 mm 0 2341 0 2346 in Exhaust 5 965 5 980 mm 0 2348 0 2354 in Service Limit Inlet 5 903 mm 0 2324 in Exhaust 5 923 mm 0 2332 in Valve Guide Inspection e Measure the inside diameter of the valve guide x If the valve guide has worn past the service limit replace the valve guide or cylin
309. ply lithium grease NLGI Grade No 2 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease WL Apply soap and water solution or rubber lubricant 13 4 BRAKES Exploded View BRAKES 13 5 Exploded View us Tig vas 54 05 C2 Brake Pipe Nipples 1 18 18 8 _ 3 RerweNus oa 30 224 4 Rear Brake Panel Mounting 44 48 32 75 Rear Wheel Cylinder Mounting Nuts 74 ors 65i Left Parking Brake Lever Linkage Left Rear Brake Drum Parking Brake Lever Right Parking Brake Lever Linkage Right Rear Brake Drum White Mark Yellow Mark Apply lithium grease NLGI Grade No 2 Apply brake fluid Apply grease Apply a non permanent locking agent Replacement Parts WL Apply soap and water solution or rubber lubricant D CES 13 6 BRAKES Specifications tem Standard Brake Fluid Type DOT3 Fluid Level Between upper and lower level lines Brake Pedal Brake Pedal Free Play 2 10 mm 0 08 0 39 in Brake Drums Brake Drum Inside Diameter 180 000 180 160 mm 7 0866 7 0929 in 180 75 mm 7 116 in Brake Panel Assemblies Brake Shoe Lining Thickness 4 5 mm 0 18 in Parking Brake Lever and Cables Parking Brake Lever Travel 8 12 notches clicks at 200 20 kof 44 Ib BRA
310. pply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In Stallation Internal Relay Inspection Service Code 34 OThe relay function is included in the EPS ECU A So the relay function can not be inspected e Turn the main switch OFF e Disconnect the EPS ECU and EPS motor connectors e Check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector lt EPS Motor Connector B R Lead Terminal C BK Lead Terminal D x If the wiring is good check the power supply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation STEERING 15 41 1008016 81 1008016 81 15 42 STEERING EPS Electric Power Steering System CPU Central Processing Unit Inspection Service Code 35 OThe CPU is built in the EPS ECU A So the CPU itself can not be inspected e Check the power supply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation Direction Distinction Circuit Inspection Service Code 36 OThe direction distinction circuit is built in the
311. r x Replace any bushings or damper that are worn cracked hardened or otherwise damaged 1 406000851 Exploded SPSCIICATIONS Saskia tx eode tous Special TOONS Steering Wheel and Main Shaft AsselTDI ica pti e Steering Wheel Position Adjustment pp Steering Wheel Free Play cies Steering Wheel Centering Steering Wheel and Steering Shaft Removal KAF950G9 Steering Wheel and Steering Shaft Installation KAF950G9 Steering Wheel and Steering Shaft Removal KAF950GD Steering Wheel and Steering Shaft Installation KAF950GD Steering Gear Assembly oteering Gear Assembly Removal Steering Gear Assembly Steering Gear Preload Adjustment Tie Rod Length Adjustment Steering Joint Dust Boot Steering Knuckles Steering Knuckle Remowval Steering Knuckle Installation Knuckle Bearing Removal Knuckle Bearing Installation Knuckle Joint Removal Knuckle Joint Installation EPS Electric Power Steering EPS System Servicing Precautions EPS System Troubleshooting Inquiries to Rider Self diagnosis Outline Self
312. r D e Install the clamps E F KAF950G9 GC HA G KAF950GD e Install Fuel Return Hose A and Clamp Fuel Output Hose B and Clamp e Run the fuel hoses and air vent hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Fuel Tank Cleaning Inspection WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank 3 36 FUEL SYSTEM Fuel Tank e Remove the fuel tank and drain it e Remove Fuel Level Gauge KAF950G9 GC HA see Fuel Level Gauge Removal Fittings A Seals B and Fuel Hoses C e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Dry the tank with compressed air e Visually inspect the following items for any damage Fuel Tank Cap Gasket Fuel Level Gauge Gasket KAF950G9 GC HA Seals Replace the gaskets if they are damaged OPush down the gasket A into the bottom of the fuel tank cap B and insert the flange portions C of the gasket to the cap threads Fuel Level Gauge Removal KAF950G9 GC HA A WARNING Fuel is extremely flammable and can be explosive under certain con
313. r rotor with the punch mark B facing inside e Install the timing gear case see Timing Gear Case Instal lation in the Crankshaft Crankcase chapter Oil Pump Inspection e Remove the timing gear case cover see Timing Gear Case Removal in Crankshaft Crankcase chapter e Set up a dial gauge A against the oil pump gear B as shown in the figure and measure the oil pump side clear ance Oil Pump Side Clearance Standard 0 030 0 096 mm 0 0012 0 0038 in Service Limit 0 15 mm 0 0059 in If the clearance exceeds the service limit go to next pro cedure e Remove the oil pump outer rotor see Oil Pump Removal e Measure the depth of the pump housing in the crankcase A with a depth micrometer B at several points Oil Pump Housing Depth Standard 12 63 12 67 mm 0 4972 0 4988 in Service Limit 12 72 mm 0 5008 in xlf the depth exceeds the service limit replace the crankcase x If the depth within the service limit replace the timing gear case e Visually inspect the oil pump inner rotor A and outer rotor B x If there is any damage or uneven wear replace the timing gear case C ENGINE LUBRICATION SYSTEM 7 11 Relief Valve Relief Valve Removal e Drain the engine oil see Engine Oil and or Oil Filter Change in the Periodic Maintenance chapter e Remove Relief Valve Bolt A and Washer Relief Valve Spring Relief Valve Plunger Relief Valve Installation e Install Re
314. rake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Air Bleeding e Tilt up the front cargo hood and remove the maintenance cover e evel the reservoir B and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary 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 line e With the reservoir cap off slowly pump the brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir This bleeds the air from the master cylinder end of the line Brake Fluid e Remove the wheel for extra clearance see Wheel Re moval in the Wheels Tires chapter e Connect a clear plastic hose A to the bleed valve at the wheel cylinder and run the other end of the hose into a container Brake Panel B NOTE OStart with the rear left or right wheel and finish with the front left or right wheel e Bleed the brake line and the caliper as follows this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake pedal A until it
315. rankshaft 3 Main Journal Runout Service Limit 0 06 mm 0 0024 in e Visually inspect the crankshaft gear teeth A e Dothe timing gear inspection procedure see Timing Gear Inspection x If the crankshaft gear teeth are damaged or worn replace the crankshaft 107004 81 CRANKSHAFT CRANKCASE 9 23 Crankshaft and Connecting Rods Crankshaft Side Clearance e Insert a thickness gauge A between the thrust washer and the crank web at the main journal to determine clearance Crankshaft Side Clearance Standard 0 02 0 24 mm 0 0008 0 0094 in Service Limit 0 30 mm 0 0118 in x If the clearance exceeds the service limit the crankshaft may be re ground and oversize thrust washers installed Oversize Thrust Washers 0 12 mm 0 0047 in Oversize e The final finishing dimensions should be as shown in the table Finishing Dimensional Specifications A 22 25 22 32 mm 0 8760 0 8787 in B R2 5 mm 0 0984 in Crankshaft 3 Main Journal Width Standard 22 00 22 07 mm 0 8661 0 8689 in Connecting Rod Big End Bearing Insert Crankpin Wear e Using plastigage press gauge A measure the bearing insert crankpin clearance NOTE O Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation ODo not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 020
316. rate correctly STEERING 15 25 86170368881 15 26 STEERING EPS Electric Power Steering System OThere are 40 and 7 5 A fuses for the EPS system If the fuse is blown the EPS system does not operate In this case the EPS warning indicator light LED does not light up and even if engine is started Replace the fuse A WARNING When replacing the 40 A fuse first disconnect the battery cables to avoid electrical shock the EPS system fuses are blown frequently inspect the EPS system parts Olf the EPS ECU was replaced be sure to register the EPS neutral position see EPS Neutral Position Registration The EPS system can not function until the neutral position is registered in the new EPS ECU In this case the EPS warning indicator light LED blinks immediately after en gine starts OIf the following parts were removed or replaced be sure to register the neutral position of the EPS see EPS Neu tral Position Registration If the neutral position does not register EPS system does not operate correctly EPS Unit Upper and Lower Universal Joints oteering Gear Assembly Steering Knuckles ODo not loosen the following bolts and nuts except repair work If the following bolts and nuts were loosened be sure to register the EPS neutral position see EPS Neu tral Position Registration If the neutral position does not register EPS system does not operate correctly Steering Gear Assembly Bracket Bolts Tie R
317. rest hole e Bend the cotter pin A over the nut B 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 e Remove the strut see Strut Front Shock Absorber Re moval e Hold the large washer A in a vise B e Remove Locknut C and Small Washer Large Washer e Remove Holder A Thrust Plate B Dust Seal Thrust Washer Upper Spring Seat C Dust Cover D opring E e Install the replaced spring OFit the spring end A to the bulge B in the lower spring seat C SUSPENSION 14 7 HJ07007BS1 J04109BS1 14 8 SUSPENSION Struts and Rear Shock Absorbers e Install Dust Cover A Upper Spring Seat B OFit the spring end to the bulge C in the dust cover and upper spring seat e Apply grease to the upper and lower side on the following parts and install them Dust Seal A Thrust Washer B OFace the projection on the thrust washer downward e Install Holder A Large Washer B Small Washer C Locknut D OPush down the holder and tighten the locknut Torque Strut Locknuts 49 N m 5 0 kgf m 36 ft Ib Struts and Rear Shock Absorbers Rear Shock Absorber Preload Adjustment The spring adjusting sleeve A on the rear shock ab sorbers have 5 positions so that the springs can be adjusted for different terrain and loading conditions If the spring a
318. rformance and can cause an accident resulting in injury or death If the brake pedal has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately e Install the removed parts see appropriate chapters Brake Pedal Play Inspection e Check the brake pedal play Brake Pedal Play Standard 2 10 mm 0 08 0 39 in x If the play is not correct adjust it e Remove the front cargo compartment see Front Cargo Compartment Removal in the Frame chapter e oosen the locknut A and turn the push rod B to obtain the correct amount of free play e Tighten Torque Push Rod Locknut 17 2 N m 1 8 kgf m 13 ft Ib e Check the brake for good braking power and no brake drag A WARNING Insufficient free play can cause brake heating and drag resulting in skidding and loss of control which could cause an accident resulting in serious injury or death Be sure the brake free play is adjusted to the specification PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Brake Master Cylinder Cup and Dust Seal Replacement e Remove the master cylinder see Master Cylinder Re moval in the Brakes chapter e Remove the piston stop bolt e Remove the dust seal A and then the retainer B with the circlip pliers Special Tool Inside Circlip Pliers 57001 143
319. rminal 1 m Wiper 5 Roof Warning Light 6 Bed Light BK W LG R W R r L Europe Model R W i BL E a De neverse Switch 2 00 1 9 H po m Reverse RAW RAY 3 Light il p BK es 0 DI ag BL BL anu ed 12V21 5WX2 SK Y IB H dll id Injection La E Neutral Switch ae Pump 1 4 Glow Plug Relay Fusible Link 50A Fuse Box BK W Fuse Box 1 i Starter Relay Fuse 30 2 Accessory Conector Fuse 20 bs s R R BL R gt _ BL R B 3 Accessory Fuse 20 s gt x ax az Glow Plugs Fuse Box 2 n E N 1 Fuse 30A Starter 2 Horn Fuse 10 lt X Preheating Motor 3 Preheating Timer Fuse bi Timer oe Pressure Temperature o Orange Switch Switch anes P Pink NEUTRAL SWITCH CONNECTIONS Purple 2 Terminal p BRAKE LIGHT SWITCH CONNECTIONS PARKING BRAKE LIGHT SWITCH CONNECTIONS OS eR JBt 8 Ground When brake pedal is pushed dom Comm When parking brake lever is pulled up C O white Neutral RPosition ma 98052 03608 W2RO360BW5 C 17 14 ELECTRICAL SYSTEM Wiring Diagram KAF950GB GC Accessory Connector 12V 120W Po
320. rn the holder one turn at a time while pressing down very lightly Check the seat after each turn NOTICE 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 327 grind return to the seat outside di ameter measurement step above e o measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above x If the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 607 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 607 grind return to the seat width mea surement step above Correct Width B GE15012231 8 15012381 ENGINE TOP END 5 19 Valves e ap the valve to the seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the
321. rn the main switch OFF Connect an auxiliary lead to the terminals of the EPS self diagnosis system connector Lift the front wheel off the ground Turn the steering wheel fully to the left and keeps it Start the engine while turning the steering wheel fully to the left Indicator light LED lights up for 4 seconds and goes Turn the main switch OFF off OK 4 seconds Free the hands from the steering wheel Indicator light LED lights up 4 seconds Turn the steering wheel fully to the left and keeps it Indicator light LED goes off 4 seconds Free the hands from the steering wheel Indicator light LED blinks two times Indicator light LED blinks three times NG Wait for 1 second or more and turn the main switch OFF 1060748 F 15 40 STEERING EPS Electric Power Steering System Power Supply Voltage Abnormal Service Code 11 12 OThe usable range of the power supply voltage is 10 V to 16 V e Check the charging condition see Alternator Operation Inspection in the Electrical System chapter x If the charging condition is normal check the power sup ply voltage see EPS ECU Power Supply Voltage Inspec tion x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation EPS Neutral Position Unregistration Service Code 31 OThis code appear
322. rottle Pedal Play 5 10 mm 0 20 0 39 in Idle Speed 850 950 r min rpm Cooling System Coolant Type Recommended Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 31 Total Amount 4 4 L 4 7 US qt Fan Belt Deflection 9 5 11 5 mm 0 37 0 45 in at 98 N 10 kgf 22 Ib Engine Top End Valve Clearance 0 20 mm 0 0079 in Converter System Belt Width 34 1 mm 1 34 in 32 6 mm 1 28 in Belt Deflection 28 36 mm 1 10 1 42 in Wear Shoe Width Engine Lubrication System Engine Oil Grade CF or CF 4 Viscosity SAE 10W 40 TERT Capacity 3 0 L 3 2 US qt When filter is not removed 3 3 L 3 5 US qt When filter is removed Oil Level Between F and L marks on dipstick Transmission Transmission Oll Type Hypoid gear oil Viscosity SAE 90 above 5 C 41 F or SAE 80 below 5 C 41 F Capacity 2 5 L 2 6 US qt Eie Oil Level Between H and L level lines on dipstick Wheels Tires Tire Tread Depth 13 2 mm 0 52 in 3 mm 0 12 in Final Drive Front Final Gear Case Oll Type Hypoid gear oil for LSD Limited Slip Differential gears Viscosity SAE 140 GL 5 or SAE 90 GL 6 Capacity 0 4 L 0 4 US qt Oil Level Filler opening level 2 12 PERI
323. rque Converter Outer Cover E Front F OThe rear left brake line is shown Brake Pipe A Nipple B Brake Hose C Retainer D Front E Brake Wear Inspection e Remove the brake drum see Brake Drum Removal in the Brakes chapter e Measure the inside diameter A of the drum at several points any measurement is greater than the service limit re place the drum x If the drum is worn unevenly or scored lightly turn the drum on a brake drum lathe or replace it Do not turn the drum beyond the service limit Brake Drum Inside Diameter Standard 180 000 180 160 mm 7 0866 7 0929 in Service Limit 180 75 mm 7 116 in e Remove the brake drum for brake shoe inspection see Brake Drum Removal in the Brakes chapter e Measure the lining thickness at several points Brake Shoe Lining Thickness Standard 4 5 mm 0 18 in Service Limit 1 0 mm 0 04 in If any measurement is less than the service limit replace both shoes as a set x If the lining thickness is greater than the service limit do the following before installing the shoes e File or sand down any high spots on the surface on the lining e Use a wire brush to remove any foreign particles from the lining e Wash off any oil or grease with an oilless solvent NOTICE 15148025 P Do not use a solvent which will leave an oily residue The shoes will have to be replaced 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures
324. ry overcharged Alternator trouble Battery faulty MODEL APPLICATION Beginning Frame No JK1AFDG1D9B500001 2009 95069 JK1AF950GGB600001 JK1AFDG1DAB502001 2010 KAF990G K4AF950GGB600601 2010 KAF950HA JK1AFDH1DAB500001 JK1AFDG1DCB505101 2012 KAF990GC K4AF950GGB601401 JK1AFDG101DB508101 2013 KAF990GD K4AF950GGB601901 L1 This digit in the frame number changes from one machine to another JK1AFDG101BB503301 uM JK1AF950GGB601001 E E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1409 05 Printed in Japan
325. s 44 N m 4 5 kgf m 32 ft Ib e Adjust the front final gear case oil see Front Final Gear Case Oil Change in the Periodic Maintenance chapter 12 10 FINAL DRIVE Front Final Gear Case Front Final Gear Case Disassembly e Remove Front Final Gear Case see Front Final Gear Case Re moval Bearing Housing Nuts A Pinion Gear Unit B e Remove the spacers A on both sides e Remove the ring gear cover bolts starting with the smaller bolts B Larger Bolts C Ring Gear Cover D e Remove the ring gear A together with the differential unit B Front Final Gear Case Assembly e Visually check the pinion gear and ring gear for scoring chipping or other damage Replace the bevel gears as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact e Replace the O ring A with a new one e Apply grease to the new O ring e Install Differential Unit and Ring Gear Ring Gear Shim B Ring Gear Cover e First tighten the 10 mm 0 39 in bolts then tighten the 8 mm 0 31 in bolts Torque Ring Gear Cover Bolts M10 47 N m 4 8 kgf m 35 ft Ib Ring Gear Cover Bolts M8 25 Nm 2 5 kgf m 18 ft Ib Front Final Gear Case e Install the pinion gear unit with the ring gear side of the case facing down e Replace the O ring A with a new one e Apply grease to the new O ring e Align the air vent passage B with the hose nipple C e Tighten
326. s trouble Direction distinction circuit for EPS torque sensor is trouble Boosting transformer circuit is trouble EPS torque sensor is trouble EPS Unit EPS motor is trouble NOTE 1 This code appears the following condition OWhen the EPS ECU was replaced and the EPS neutral position is not registered in the new EPS ECU In this case the EPS warning indicator light LED blinks immediately after engine starts But the service code 31 is not memorized in the EPS ECU Therefore the service code 31 will disappear when the EPS neutral position was registered in the new EPS ECU 15 34 STEERING EPS Electric Power Steering System Self diagnosis Flow Chart Turn the main switch OFF Connect an auxiliary lead to the terminals of the EPS self diagnosis system connector start the engine Self diagnosis mode starts The EPS warning indicator light LED blinks to display the service code Turn the main switch OFF Check the content of displayed service code s with the service code table and solve the problem according to the inspection procedure of each service code Erase the service code memorized in the EPS ECU with the service code erase mode Disconnect the auxiliary lead from the terminals of the EPS self diagnosis system connector NG lit Start the engine and confirm that the EPS warning indicator light LED goes off and EPS operates correctly End 10080228 EPS Electric
327. s in the following condition OWhen the EPS ECU was replaced and the EPS neutral position is not registered in the new EPS ECU e Register the EPS neutral position in the new EPS ECU see EPS Neutral Position Registration Current Sensor Inspection Service Code 32 OThe current sensor is built in the EPS ECU A So the current sensor itself can not be inspected e Turn the main switch OFF e Disconnect the EPS ECU and EPS motor connectors e Check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector A EPS Motor Connector B R Lead C BK Lead D x If the wiring is good check the power supply voltage see EPS ECU Power Supply Voltage Inspection x If the power supply voltage is good but the problem still exists replace the EPS ECU see EPS ECU Removal In stallation 1008016851 EPS Electric Power Steering System FET Field Effect Transistor Inspection Service Code 33 OThe FET is built in the EPS ECU A So the FET itself can not be inspected e Turn the main switch OFF e Disconnect the EPS ECU and EPS motor connectors e Check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection EPS ECU Connector EPS Motor Connector B R Lead Terminal C BK Lead Terminal D x If the wiring is good check the power su
328. s not fully charged additional charging time is necessary Sealed Type Battery e Charge the battery according to the battery terminal volt age WARNING This battery is sealed battery type Never remove seal sheet or cap A even at charging Never add water Charge with current and time as stated be low e Refer to the Battery Charging Time Table for the charging Battery Charging Time Table at 27 C 80 F e Determine battery condition after charging ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below 12 0 12 6 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable Replace Battery Testing Chart Conventional Type Battery Once battery is in an adequate state of charge the fol lowing load test procedure will be valid The load test is undertaken to determine if the battery has adequate elec trical performance or if it has to be replaced Important This procedure is valid only it the battery is at or above the state of check specified in STEP 2 ELECTRICAL SYSTEM 17 31 17 32 ELECTRICAL SYSTEM Battery Battery Testing Chart STEP 1 STEP 2 ELECTROLYTE LEVEL Electrolyte levels at the bottom of split rings water cannot be added Specific Gravity below 1 065 STEP 3 LOAD TEST 1 Connect voltmeter and ampere load equal to 1 2 CCA rating of the ba
329. se Piston Removal e Remove Connecting Rod see Connecting Rod Removal Snap Rings A Special Tool Inside Circlip Pliers 57001 143 e Remove the piston pin Special Tool Piston Pin Puller Assembly A 57001 910 e Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE18060831 Piston Installation e Apply engine oil to the piston pin e Align the arrow A on the piston and ID mark B on the connecting rod e Install Piston Pin New Snap Rings Special Tool Inside Circlip Pliers 57001 143 e Install the oil ring coil expander making sure the wire is completely inserted into the coil expander COIL EXPANDER CRANKSHAFT CRANKCASE 9 29 Pistons and Crankcase e Install Oil Ring Coil Expander Oil Ring A Second Ring B Top Ring C OThe second and top rings must be installed with the mark D facing up e Position each piston ring end gap as shown in the figure Arrow A Top Ring End Gap B Second Ring End Gap C Oil Ring End Gap D Crankcase Removal e Remove Connecting Rods see Connecting Rod Removal Crankshaft see Crankshaft Removal Crankcase A 11060038851 Crankcase Warp e Clean the crankcase e Lay straightedge A across the upper surface of the crankcase at several different poin
330. seat until the grinding com pound produces a smooth matched surface on both the seat and the valve 8 ORepeat the process with a fine grinding compound Lapper A Valve Seat B GE15012081 6 Valve C e he seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter 5 20 ENGINE TOP END Valves Valve Seat Repair START Machinist s dye on seat Tool Purpose 45 Grind 45 Cutter make seating area smooth and round Measure Seating Area Outside Tool Purpose Too small 45 Grind 45 Cutter increase outside diameter of seat Tool Purpose area to specification Tool Purpose Too narrow 45 Grind Tool 45 Cutter Purpose increase width of seat area beyond specification to increase outside diameter Tools Purpose Measure Seating Width Vernier Caliper Lap Valve Diameter Vernier Caliper check seat outside diameter against specification Results Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce outside diameter of seat area to s
331. section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation Indicates a procedural step or work to done Olndicates 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 what action to take based on the results of the test or inspec 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 parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Em mmm
332. si 14 465 14 955 kPa 147 5 152 5 kgf cm 2 098 2 169 psi 850 950 r min rpm 3 800 3 900 r min rpm 0 81 0 03 mm 0 0319 x0 0012 in 0 81 0 02 mm 0 0319 0 0008 in 1013001851 FUEL SYSTEM 3 9 Special Tool Dial Gauge Adapter 57001 1430 875714308 3 10 FUEL SYSTEM Throttle Pedal and Cable Throttle Pedal Play Inspection e Refer to the Throttle Pedal Play Inspection in the Periodic Maintenance chapter Throttle Pedal Play Adjustment e Refertothe Throttle Pedal Play Adjustment in the Periodic Maintenance chapter Full Throttle Pedal Position Adjustment e oosen the locknut A e Screw in the throttle pedal stop bolt B e ilt up the cargo bed e Remove Injection Pump Cover Bolts A and Collars Injection Pump Cover B e Reinstall the collars A and tighten the pump cover bolts B together with the bracket C temporary e Depress the throttle pedal until the speed control lever A on the injection pump is in the fully opened position and hold it there e the throttle pedal stop bolt until the bolt head lightly touches the bottom of the throttle pedal e Tighten the locknut securely Throttle Pedal and Cable Throttle Cable Installation e Run the throttle cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the throttle pedal play adjustment see Throttle Pedal Play Adjustment in the Periodic Maintenance ch
333. sition e Using the shift shaft lever A temporarily set the shift arm B in forward or reverse position as shown in the figure e Put the differential shift lever A in LOCK position e Turn the hi low shift shaft lever A clockwise while turning the drive shafts wheels until the lever engages low gear TRANSMISSION 10 15 Transmission and Shift Mechanism e Screw the joint A of the shift shaft lever B fully into the hi low shift cable C end and install the cable onto the bracket D e Line up the punch mark A on the shift arm projection B on the transmission case and slit opening in the shift shaft lever C e Tighten Shift Shaft Lever Nut D Shift Shaft Lever Clamp Bolt E e Hold the shift shaft lever A in the low range position turning fully clockwise and then push the outer cable B lightly rearward to remove the cable free play e Tighten Shift Cable Adjuster Nut C Shift Cable Adjuster Nut D e Put the shift lever A in the center of right and left at N NEUTRAL position and hold it at the location B suitable plates C between the shift lever and lower and upper side of the gate in order to fix the shift lever e Using the shift shaft lever A temporarily set the shift arm B in neutral position as shown in the figure 10 16 TRANSMISSION Transmission and Shift Mechanism e Screw the joint A of the shift shaft lever B fully int
334. ssist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Wiring open or shorted Main switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor trouble Pinion or ring gear worn Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Camshaft seizure No fuel flow No fuel in tank Fuel tank air vent obstructed Fuel injection pump trouble Fuel filter clogged Fuel line clogged Compression low Fuel injection nozzle loose Glow plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing APPENDIX 18 31 Fuel tank air vent obstructed Fuel injection pump trouble Compression low Fuel injection nozzle loose Glow plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston w
335. starter motor will not turn over or the current may burn out the starter motor windings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was brought on by some other item or items they too must be repaired or replaced or the replacement part will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature ELECTRICAL SYSTEM 17 23 17 24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x1 O range and read the tester x If the tester does not read 0
336. t 17 3 Fuel Fiter Mounting Bos 20 20 18 4 Fuel injection Nozzles s 44 5 Fuel injection Pipe Clamp Bots 74 075 6 Fuel injection Pipe Mounting nus 25 28 18 Fuel injection Pump Bracket Bots 20 20 15 8 Fuel injection Pump GearNut_ 6 68 a 9 Fuel injection Pump Mounting Nus 20 20 15 710 idie Adjusting Screw Locknut 69 970 Linkage Pipe Nuts 28 20 12 Maximum Speed Set Screw Locknut 69 00 oime 713 Fuel Level Gauge Mounting Bots 40 os 35imb 14 Air Vent Hose 15 Check Valve 16 Fuel Output Hose from Fuel Filter to Fuel Injection Pump 17 Fuel Output Hose from Fuel Tank to Fuel Filter 18 Fuel Return Hose from Fuel Injection Pump to Fuel Tank AD Apply adhesive G Apply grease R Replacement Parts 3 8 FUEL SYSTEM Specifications tem Standard 5 10 mm 0 20 0 39 in Throttle Pedal and Cable Throttle Pedal Play Fuel Injection Nozzle Fuel Injection Nozzle Injection Pressure Marking of Injection Nozzle Red or Green None Fuel Injection Pump Idle Speed Maximum Engine Speed No Load Injection Timing Plunger Stroke Marking of Injection Nozzle Red or Green None Injection Nozzle Mark Position A 13 239 14 220 kPa 135 145 kgf cm 1 920 2 062 p
337. t A e urn the idle adjusting screw B at the injection pump until the idle speed is correct e Tighten Torque Idle Adjusting Screw Locknut 6 9 0 70 kgf m 61 in Ib e Open and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Fuel Hoses and Connections Inspection e Tilt up the cargo bed and seat e Check the fuel hoses and fittings for deterioration cracks and signs of leakage Replace the fuel hose if any fraying leak A cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are installed correctly e When installing run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed x Replace the hose if it has been sharply bent or kinked Fuel Hoses Replacement e ilt up the cargo bed and seat e Remove Front Seat Lower Cover Front see Floor Center Panel Removal in the Frame chapter Clamps A Fuel Hoses B 6505006851 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Clamps A Fuel Hoses B e Remove Clamps A Fuel Hoses B e Remove Clamp A Fuel Hose B Fuel Filter Mounting Bolts C e Remove Clamps A Fuel Hoses B
338. t 6 5 4T Fuel Injection Pump Mounting Nuts 2 0 15 Idle Adjusting Screw Locknut 0 70 61 in lb Linkage Pipe Nuts 2 8 20 61 in lb 35 in lb Maximum Speed Set Screw Locknut Fuel Level Gauge Mounting Bolts KAF950GD Cooling System Coolant Drain Plug 18 Coolant Inlet Bolts Coolant Reserve Tank Bolt Coolant Temperature Switch Fan Mounting Bolts Radiator Fan Mounting Bolts Radiator Fan Switch KAF950GB Radiator Fan Switch KAF950G9 GA HA Radiator Mounting Bolts Radiator Screen Mounting Bolts Shroud Mounting Bolts Thermostat Housing Cap Bolts Water Pipe Mounting Bolts Water Pump Mounting Bolts and Nuts 69 1 39 1 16 20 78 1 16 53 16 17 18 78 1 16 78 1 16 53 69 1 10 78 1 16 15 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Engine Top End Cylinder Head Bolts 34 3 5 25 EO S Cylinder Head Cover Nuts 5 4 0 55 48 in lb Exhaust Manifold Mounting Nuts 20 2 0 15 Inlet Manifold Mounting Bolts 7 8 0 80 69 in Ib Inlet Manifold Mounting Nuts 7 8 0 80 69 in Ib Rocker Arm Components Mounting Nuts 15 Valve Adjusting Screw Locknuts 97 in lb Muffler Mounting Bolts 15 Converter System Air Cleaner Housing Mounting Bolts late models and KAF950GB Air Cleaner Housing Mounting Bolts KAF950G9 and KAF950GA HA early models Converter Case Bolts L 55 mm 20 L Converter Case Bolts L 28 mm 15 12 15
339. t sequence using the procedures shown Backlash Adjustment e Check and adjust the gear backlash when any of the backlash related parts are replaced with new ones e Install the drive gear with the primary shim and assemble the driven gear with the primary shim Do not install the bevel gear case holder during adjustment e Clean any dirt and oil off the bevel gear teeth e Install the bevel gear case and tighten the case bolts OCheck the backlash while tightening the case bolts Stop tightening them immediately if the backlash disappears and change the shim to a thinner one e Hold the driven gear shaft A with a vice OProtect the driven gear shaft with aluminum plates B e Set up a dial gauge C against the middle point D of the gear dog side E OThe middle point is position at about 23 5 mm 0 925 in F from center Gear Dog G e To measure the backlash turn the shaft clockwise and counterclockwise The distance between the highest and lowest gauge reading is the amount of backlash x If the backlash is not within the limit replace the shim s at the drive and or driven gear To increase backlash de crease the thickness of the shim s To decrease back lash increase the thickness of the shim s x Change the thickness a little at a time e Recheck the backlash and readjust as necessary Bevel Gear Backlash Standard 0 15 0 59 mm 0 0059 0 0232 in at middle of gear dog side on drive gear shaft
340. t turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Insert the new bulb in the socket A e Install the socket into the speedometer B Headlight Removal e Remove Front Cover see Front Cover Removal in the Frame chapter Bolts A KAF950F9 FB Screws A KAF950FC Screws B Headlight Installation OCheck that the clip nuts A are in place as shown in the figure e For the KAF950F9 FB tighten the bolts and screws e For the KAF950FC tighten the screws e Install the front cover see Front Cover Installation in the Frame chapter Reverse Light Switch Installation EUR Model e Put the transmission shift lever in the REVERSE position e Install the reverse light switch bracket A on the reverse shift lever so that the switch rod B contacts the boss C and the clearance is 1 2 mm 0 04 0 08 in E e Tighten the shift shaft lever clamp bolt D securely Lighting System Lighting System Circuit BL RdT K I BL R lt SEES CLE 2 m BR BR BR W W R BK BK Y R BK BK Y 9 ana Speedometer Illumination Oil Pressure Warning Indicator Light Coolant Temperature Warning Indicator Light Parking Brake Indicator Light Light Switch Indicator Light Light Switch Main Switch Headlights Brake Light Switch Coolant Temperature Switch Parking Brake Light Switch
341. te the following OReplace the nut with a new one Radiator Side Cover Removal e Remove Tapping Screws A Bolt B e Remove the front guard mounting nut C temporary and remove the radiator side cover D Front Side Cover Removal e Remove Screws A and Collars Quick Rivets B Front Side Cover C FRAME 16 31 Covers Front Side Cover Installation e nstall the front side cover note the following parts A B size Screw L 16 mm 0 63 in and Collar L 4 mm 0 16 in Screw L 16 mm 0 63 in and Collar L 6 mm 0 24 in Quick Rivets C Rear Side Cover Removal e Remove Screws A and Collars Tapping Screws B and Collars Quick Rivets C Rear Side Cover D Rear Side Cover Installation OCheck that the clip nuts A are in place as shown in the figure e Install the rear side cover note the following parts B C D size Screws L 16 mm 0 63 in and Collars L 4 mm 0 16 in screw L 16 mm 0 63 in and Collar L 6 mm 0 24 in Tapping Screws D L 16 mm 0 63 in and Collars L 4 mm 0 24 in Quick Rivets E Middle Cover Removal e Remove Tapping Screws A and Collars Quick Rivets B Screw C and Collar Middle Cover D 16 32 FRAME Covers Middle Cover Installation e Install is the reverse of removal note the following OCheck that the clip nuts A are in place as shown in the figure Flap Cover Removal
342. teda aa Shift Lever POSITION AC USIMENT se es Transmission Shift Cable Inspection pp Transmission ISemioVal ss taa Ete br v tnn Cl Transmission ead inia co c PE x oe du ba v ve neon eds Transmission and Shift Mechanism Inspection pp Hi Low Gears and Shift Mechanism pp VEOW Shirt Gable InstallallOFi uina er v DL ret eed e has Be Hi Low Shift Cable Inspection pp Hi Low Gear and Shift Mechanism Removal pp Hi Low Gear and Shift Mechanism Installation pp Hi Low Gear and Shift Mechanism Inspection pp 2WDAWD Smt Mechans pls tuo ao Fa rte severe vica t totae Qu cus 2WD AWD Shift Cable Adjustment pp 2WD AWD Shift Cable LubricatiOn ii base a esee ea c ce er e d e 2WD AWD Shift Cable Inspection enn nnnm nnne 2WD AWD Shift Mechanism Removal nennen nnns 2WD AWD Shift Mechanism Installation pp 2WD AWD Shift Mechanism Inspection pp Differential Gears and Shift Mechanism pp Differential Shift Cable Adjustment pp Differential Shift Cable Lubrication pp Differential Shift Gable Inspection m E a Differential Shift Mechanism Removal pp Differential Shift Mechanism Installation pp Differential Shift Mechanism Inspection pp Differential Gear REMOVAL Differential Gear Installation ere rix tes acce o n an CR i het cc Reto ac ss Differential Gear Inspection
343. ter line of the nozzle e Ensure that the nozzle does not drip Fuel Injection Pump Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Maximum Engine Speed Inspection e Check the full throttle pedal position see Full Throttle Pedal Position Adjustment e Set the parking brake e Be sure the transmission is in neutral e Start the engine and warm it up thoroughly e ilt up the cargo bed e Check the maximum engine speed with a suitable tachometer Maximum Engine Speed No Load Standard 3 800 3 900 r min rpm If the maximum engine speed is not in the specified range adjust it Maximum Engine Speed Adjustment e Set the parking brake e Be sure the transmission is in neutral e ilt up the cargo bed e Remove the fuel injection pump cover see Full Throttle Pedal Position Adjustment e Cut and remove the wire A on the maximum speed set screw B e Start the engine and warm it up thoroughly e oosen the locknut C e Turn the maximum speed set screw until the maximum engine speed is correct e Tighten Torque Maximum Speed Set Screw Locknut 6 9 0 70 kgf m 61 in Ib e Lock the maximum speed set screw with a wire or paint on the locknut and pump housing Fuel Injection Pipe Removal A WARNING Fuel is extremely flammable and can be
344. terioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly VOY QOD va 59 JL po 1119 Ni a A 25 5 5 igs L n 5 1 06001851 Coolant Change A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Tilt up the front cargo hood e Remove Quick Rivets A Tapping Screw B and Collar Partition C e Remove the coolant reserve tank mounting bolts A e Remove the cap B and poor the coolant into a container e Install the removed parts except the cap e Remove the front final gear case skid plate see Front Final Gear Case Oil Level Inspection in the Final Drive chapter e Place a container under the drain plugs e Remove the coolant drain plugs A at water pipes e Place a funnel under the drain hole e Remove the radiator cap A in two steps OFirst turn the
345. the pinion gear slotted nut is loosened even if the purpose is not to replace the parts check and adjust the bearing preload FINAL DRIVE 12 13 1104020881 12 14 FINAL DRIVE Front Final Gear Case e Fit the toothed washer claw A into the shaft e Apply molybdenum disulfide oil solution to the threads and seating surface of the pinion gear slotted nut and tighten it Torque Pinion Gear Slotted Nut 118 N m 12 0 kgf m 87 0 ft Ib x If none of the toothed washer tabs B align tighten the nut further just enough to align one of the tabs with a slot C in the nut e Bend the tab over the nut Front Final Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load the tapered roller bearings must be properly preloaded Also the backlash distance one gear will move back and forth without moving the other gear and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged Above three adjustments are of critical importance and must be carried out following the correct sequence and method e When any one of the backlash related parts are replaced or the pinion gear nut is loosened even if the purpose is not to replace the parts check and adjust the bearing preload the bevel gear backlash and tooth contact by replacing shims e he amount of backlash is influenced by the ring gear position more than by the pinion gear
346. the switch position turn the adjusting nut B Brake Light Switch Timing Standard ON after 10 mm 0 39 in of pedal travel NOTICE To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime ubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation Pivots and Points Lubricate with Grease 2WD AWD Shift Lever Pivot Brake Pedal Pivot Cargo Bed Mounting Pins Differential Shift Lever Pivot Propeller Shaft Bearing A under Fuel Tank Seat Brackets Throttle Pedal Pivot Transmission Shift Lever Pivot OGrease the propeller shaft bearing using the grease nip ple B Cables Lubricate with Grease 2WD AWD Shift Cable Differential Shift Cable Parking Brake Cables Throttle Cable Cables Lubricate with Rust Inhibitor 2WD AWD Shift Cable Differential Shift Cable Throttle Cable 1504000851 6604011451 PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures e With the cable disconnect at both ends the cable should move freely A within the cable housing x If
347. 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 this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man ual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main 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 make 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 engine oil informa tion use the Quick Reference Guide to locate the Engine Lubrication System chapter Then use the Table of Contents on the first page of the chapter to find the Engine Oil
348. to sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle BO2001B 5 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 limits on 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 cotter pins or self locking nuts must be replaced with new ones whenever disassembled 68020108 5 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 68020118 5 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence
349. to see if fuel Defective fuel injection injection nozzle IS nozzle functioning properly 2008 No good iud Parage SECUN Retighten or replace pipe pipe section Voltage is Check to see if fuel cut No good With main switch turned applied Defective fuel cut solenoid is functioning ON check to see if voltage solenoid is applied to fuel cut solenoid properly Good No voltage is applied No good Check to see if pump is full 1 Defective fuse of fuel 2 Defective main switch Good 1 Airis sucked or fuel is N leaking from fuel inlet Check to see if fuel is ge hose joint section and leaking from distributor fuel filter head bolt 2 Fuel filter clogged Good Malfunctioning injection Tighten distributor head pump bolt or replace washer 10120008 Fuel Injection Pump Troubleshooting Unstable Idling Check to see if throttle cable is No good adjusted properly Good No good Check to see if idling speed is too low Good Check to see if air is sucked from fuel No good inlet hose joint section and fuel filter Good No good Check to see if fuel is leaking Good No good Check to see if fuel filter is contained water Good No good Check to see if fuel injection nozzle is functioning properly Good Check to see if injection timing is No good proper Good Malfunctioning injection pump FUEL SYSTEM 3 23 Adjust throttle cable Adjust idling speed
350. tor light LED blinks two times NG OK Turn the main Switch OFF within 5 seconds after indicator light blinks two times 10000238 F EPS Electric Power Steering System EPS Neutral Position Registration NOTE OKeep the self diagnosis system connector terminals connected during the EPS neutral position registration with an auxiliary lead OBe sure to lift the front wheel off the ground The EPS neutral position can not be registered correctly with the front wheel on the ground OThe EPS motor does not operate during EPS neutral position registration e Register the EPS neutral position with the following pro cedure OFirst turn the main switch OFF OSecond connect an auxiliary lead to the terminals of the EPS self diagnosis system connector by the same pro cedure as self diagnosis mode see Self diagnosis Pro cedure OThird lift the front wheel off the ground OFourth turn the steering wheel fully to the left and keep it OFifth start the engine while turning the steering wheel fully to the left OThe EPS warning indicator light LED ights up for 4 sec onds and goes off xlf the EPS warning indicator light LED remains lit or blinks turn the main switch OFF and repeat from fourth procedure again OSixth free the hands from the steering wheel after indica tor light goes off OAfter 4 seconds the EPS warning indicator light LED lights up OSeventh turn the steering wheel fully to the left and ke
351. tral Switch 15 1 5 11 Shift Arm Positioning Bolt 37 3 8 27 shift Shaft Stop Bolt 7 8 0 80 69 1 1 Transmission Case Bolts 8 8 0 90 78 in Ib Transmission Case Mounting Nuts 44 4 5 32 R Transmission Oil Drain Plug Wheels Tires Wheel Nuts Final Drive Bearing Holder 118 12 0 87 0 L Bevel Gear Case Bolts 22 2 2 16 Bevel Gear Case Holder Nuts 25 2 5 18 Differential Case Cap Bolts 32 3 3 24 L Drive Gear Nut 118 12 0 87 0 MO Drive Shaft Cap Bolts 20 2 0 15 Driven Gear Shaft Nut 108 11 0 79 7 L Front Axle Cap Bolts 8 8 0 90 78 in lb Gear Case Bracket Bolts 44 4 5 32 Gear Case Mounting Nuts 44 4 5 32 R Grease Nipple 2 3 0 23 20 in Ib G Housing Locknut 118 12 0 87 0 L Oil Drain Plug 20 2 0 15 Oil Filler Cap 29 3 0 21 Pinion Gear Bearing Housing Nuts 25 2 5 18 Pinion Gear Slotted Nut 118 12 0 87 0 Propeller Shaft Bearing Housing Cover Bolts 3 4 0 35 30 in Ib Ring Gear Bolts 82 8 2 61 L Ring Gear Cover Bolts M10 47 4 8 35 2 8 PERIODIC MAINTENANCE Torque and Torque and Locking Agent Agent _ fee es Po Ring Gear Cover Bolts M8 2 9 Speed Sensor Bolt 8 8 0 90 78 in lb Brakes Bleed Valves 48 in lb Brake Hose Banjo Bolts 18 Brake Pipe Nipples 13 Front Axle Nuts 145 Front Brake Panel Mounting Bolts l 32 Front Wheel Cylinder Mounting Bolts 91 in Ib Master Cylinder Reservoir Cap 30 in Ib Piston Stop Bolt 78 in lb Push Rod Locknut 13 Rear Axle Nuts 224 Rear Brake Panel Mounting Bolts 32 Rear Wheel Cy
352. trut Front Shock Absorber Installation aa 14 6 siet obe re a a recu aua deo 14 7 Rear Shock Absorber Preload Adjustment pp 14 9 Rear SNOCK ADSOFDSE REMOVA over HEROS 14 9 Rear Shock Absorber InstallatlOn oce e t rr tad up Gd ela rat 14 9 Shock Absorber INSPECTION zs do bee pote Co ER ut Rv xa 14 10 Front SUSPENSION reti cad Cun d 14 11 Front Suspension Arm REMOVAL ccceccseceseeeeeecceeceeeceeeteeeteeteeeteecseeseeeeueeseeeseeeseeeeeees 14 11 Front Suspension Arm Installation pp 14 11 Front SUSPENSION Arm InspectlObau iicet eni vivet iuda Sex as Culto futt 14 12 tear Spings Da 14 13 etas toutes soni ne Luc Ld netu tum oiu 14 13 Leal Spino msialauei TTE 14 14 Leaf 219519 14 14 14 2 SUSPENSION Exploded View SUSPENSION 14 3 Exploded View 6 Rear Shock Absorber Mounting Nus Smtlokmts 79 Strut Mounting Locknuts Tie Rod End Nuts G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement Parts S Follow the specified tightening sequence WL Apply soap and water solution or rubb
353. ts 44 N m 4 5 kgf m 33 ft Ib FRAME 16 35 ELECTRICAL SYSTEM 17 1 Electrical System Table of Contents Exploded Wiring Diagram KAF950G9 Wiring Diagram KAF950GB Wiring Diagram KAF950GD Specifications Special Tools Parts LOCATON itus in Dno uen n x Electrical Wiring Wiring Inspection coe ictibus aso Battery Removal Battery Installation Electrolyte Level Inspection Conventional Type Battery Electrolyte Specific Gravity Inspection Conventional Type Charging Condition Inspection Conventional Type Battery Initial Charging Conventional Type Battery Charging Condition Inspection Sealed Type Battery Ordinary Charging Battery Testing Chart Conventional Type Battery EE Alternator Removal Alternator Installation Alternator Disassembly Alternator Assembly Alternator Operational Inspection Stator Coil Inspection Rotor Coil Inspection Slip Ring Cleaning
354. ts and measure the warp by inserting a thickness gauge B between the straightedge and the crankcase Crankcase Warp Service Limit 0 08 mm 0 0031 in x If the warp exceeds the service limit crankcase may be resurfaced to the service limit of the crankcase height A Crankcase Height Standard 238 70 239 30 mm 9 3976 9 4212 in Service Limit 238 60 mm 9 3937 in xlf the height is less than the service limit replace the crankcase 1106004851 9 30 CRANKSHAFT CRANKCASE Pistons and Crankcase Crankcase Wear Cylinder Bore e Take a side to side and a front to back measurement at each of the 3 locations total of 6 measurements shown in the figure x If any of the measurements exceeds the service limit the cylinder will have to be bored to oversize and then honed 10 mm 0 39 in A 45 mm 1 77 in B 20 mm 0 79 in C Cylinder Inside Diameter Standard 72 00 72 03 mm 2 8346 2 8358 in Service Limit 72 105 mm 2 8388 in or more than 0 035 mm 0 0014 in difference between any two measurements Valve Lifter Bore Valve Lifter Bore Inside Diameter Standard 18 018 mm 0 7094 in Service Limit 18 05 mm 0 7106 in Camshaft Bearing Camshaft Bearing Inside Diameter Service Limit 36 06 mm 1 4197 in xIf the diameter exceeds the service limit replace the camshaft bearing Piston Diameter e Measure the piston diameter A at the point shown with a micrometer Piston Diam
355. ts for a short circuit 8 19040181 Housing A Terminals C Fuse Element B Blown Element D NOTE Olf the engine is operated under the condition which the battery needs refreshing charge a main fuse may blow out due to a mass current flows to the battery NOTICE When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components APPENDIX 18 1 Appendix Table of Contents Cable Wire ahd TOSS 18 2 18 Gude 18 31 18 2 APPENDIX Cable Wire and Hose Routing KAF950G9 GC HA Cable Wire and Hose Routing 5 Accessory Terminal Main Switch Band EPS ECU Hour Meter EPS Warning Indicator Light LED Glow Plug Light Parking Brake Indicator Light Speedometer Cable Speedometer Illumination Coolant Temperature Warning Indicator Light Oil Pressure Warning Indicator Light Light Switch Band To Left Headlight Band EPS Motor Connector Band EPS Torque Sensor Connector Band To Right Headlight Front Detail A Accessory Terminals Band Front Clamp Detail B Detail C 25 mm 0 98 in To Horn Switch APPENDIX 18 3 18 4 APPENDIX Cable Wire and Hose Routing KAF950GD Cable Wire and Hose Routing Acc
356. ttery for 15 seconds 2 Observe voltage at 15 seconds with load on 3 Refer to right voltage chart Voltage below Voltage equal or chart value above chart value VISUAL INSPECTION Check for damage leaks etc Battery Charging Guide Remove surface charge load at 1 2 CCA for 15 seconds or as manufacturer specifies No obvious damage Proceed to step 2 SIATE OF CHARGE Level OK water has been added Stabilized voltage below 12 4 V or specific gravity below 1 225 stabilized voltage above 12 4 V specific gravity above 1 255 Proceed to step 3 Charge according to Proceed to step 3 VOLTAGE CHART Estimated Electrolyte Temperature Minimum required voltage under load at 15 seconds 219 70 F and above 16 60 10 C 50 F 9 3 V 7 20 F 8 9 V 129 10 8 7 V 17 8 0 10080138 ELECTRICAL SYSTEM 17 33 Alternator Alternator Removal e Remove Fan Belt Cover see Cooling Fan Belt Inspection in the Periodic Maintenance chapter Alternator Terminal Locknut A Alternator Lead Connector B e Remove Alternator Adjusting Bracket Bolt A Alternator Mounting Bolt B Alternator C Alternator Installation e Clean the alternator legs and alternator bracket where the alternator is grounded e Adjust the fan belt deflection see Cooling Fan Belt In spection in the Periodic Maintenance chapter e Tighten Torque A
357. ture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts TO Apply transmission oil 10 8 TRANSMISSION Specifications tem Standard Transmission Oil Type Hypoid gear oil Viscosity SAE 90 above 5 C 41 F or SAE 80 below 5 C 41 F Capacity 2 5 L 2 6 US qt Cil Level Between H and L level lines on dipstick Transmission and Shift Mechanism Shift Arm Pin Diameter 7 95 8 00 mm 0 313 0 315 in 7 8 mm 0 307 in Shifter Block Inside Diameter 8 05 8 10 mm 0 317 0 319 in 8 2 mm 0 323 in Shifter Block Outside Diameter 13 95 14 00 mm 0 549 0 551 13 8 mm 0 543 in Shifter Groove Width 14 0 14 2 mm 0 551 0 559 in 14 3 mm 0 563 in Drive Chain 20 Link Length 158 76 159 18 mm 161 1 mm 6 343 in 6 250 6 267 in Hi Low Gears and Shift Mechanism Shifter Block Outside Diameter 13 95 14 00 mm 0 549 0 551 13 8 mm 0 543 in Shifter Groove Width 14 05 14 15 mm 0 553 0 557 14 3 mm 0 563 in 2WD AWD Shift Mechanism Shifter Block Outside Diameter 13 95 14 00 mm 0 549 0 551 13 8 mm 0 543 in Shifter Groove Width 14 0 14 2 mm 0 551 0 559 in 14 3 mm 0 563 in Differential Gears and Shift Mechanism Shift Arm Pin Diameter 8 4 8 6 mm 0 331 0 339 in 8 3 mm 0 327 in Shifter Groove Width 9 0 9 1 mm 0 354 0 358 in 9 2 mm 0 362 in TRANSMISSION 10 9 Special Tools and Sealant Outside Circli
358. tween the upper MAX and lower MIN level lines OLook the fluid level through the hole A in the control panel If the fluid level is lower than the lower level line check for fluid leaks in the brake lines and fill the reservoir to the upper level line A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified e Tilt up the front cargo hood e Remove Rubber Cap A en p PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures e Fill the reservoir to the upper level line A Upper Level Line MAX Lower Level Line MIN B Hole C of Front Cargo Compartment e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake pedal has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately Brake Fluid Change e Tilt up the front cargo hood e evel the brake fluid reservoir A N
359. uckle ORemove the tie rod end from the steering knuckle using a suitable joint remover see Steering Gear Assembly Re moval NOTICE Do not loosen the tie rod end locknuts C or the toe in of the front wheels will be changed e Remove Brake Hose Retainer D Cotter Pin Strut Clamp Bolt and Nut E e Remove Cotter Pin Front Suspension Arm Joint Nut A Front Suspension Arm Joint from Steering Knuckle ORemove the front suspension arm joint from the steering knuckle using a suitable joint remover see Steering Gear Assembly Removal e Remove the steering knuckle B Steering Knuckle Installation e Using a cleaning fluid clean off any oil or dirt on the ta pered portions of the front suspension arm joint and the tie rod end joint and the tapered holes of the steering knuckle and the front suspension arm Then dry them with a clean cloth e Apply grease to the following portions Axle Bearing Grease Seal Lips Front Suspension Arm Joint Boot Sealing Surfaces A e Tighten Torque Strut Clamp Nuts 98 10 0 kgf m 72 3 ft Ib Front Suspension Arm Joint Nuts 78 8 0 kgf m 58 ft Ib Tie Rod End Nuts 34 Nm 3 5 kgf m 25 ft lb STEERING 15 17 15 18 STEERING Steering Knuckles e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30
360. ucting self diagnosis Otherwise the EPS warning indi cator light LED blinks very slowly or does not blink OKeep the EPS self diagnosis system connector termi nals connected during self diagnosis with an auxiliary lead e Turn the main switch OFF e ilt up the front seat e Disconnect the EPS self diagnosis system connector A e Connect an auxiliary lead A to the terminals of the EPS self diagnosis system connector B as shown Auxiliary Lead Connections BL Lead C lt gt BK Y Lead D OThe BK Y lead terminal is connected to the battery terminal e Start the engine e Count the blinks of the indicator light to read the service code see Service Code Reading NOTE OKeep connections of the auxiliary lead until you finish reading the service code there is no service code the EPS warning indicator light LED remains lit and service code is not indicated e Any of the following procedures ends the self diagnosis mode OWhen the main switch is turned OFF OWhen the auxiliary lead is disconnected from the termi nals of the EPS self diagnosis system connector STEERING 15 31 1008008851 15 32 STEERING EPS Electric Power Steering System Service Code Reading OService codes are shown by a series of long and short blinks of the EPS warning indicator light LED as shown below ORead 10th digit and unit digit as the EPS warning indicator light LED blinks OThe EPS ECU can memorize all
361. ulator C is defective and must be replaced Alternator Ball Bearing Inspection NOTICE Do not disassemble the alternator for bearing in spection since disassembling the alternator dam ages the bearings e Turn the alternator rotor shaft back and forth while check ing for play roughness or binding of bearings x If bearing play roughness or binding is found disassem ble the alternator and replace the bearings ELECTRICAL SYSTEM 17 39 Alternator Alternator Circuit 1909012882 Main Switch Battery Fusible Link 50 A Load Alternator Stator Coil Rotor Rectifier Regulator 10 Main Fuse 30 A 11 Fuse Box 2 17 40 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal e ilt up the cargo bed e Remove Starter Motor Lead Connector A Starter Motor Cable B Starter Motor Mounting Bolts C Starter Motor D Starter Motor Installation e Clean the mating surface A of the starter motor and the end plate where the starter motor is grounded e Apply liquid gasket A to the mating surface as shown in the figure Sealant Three Bond 1207F e Install the starter motor and tighten the mounting bolts Torque Starter Motor Mounting Bolts 39 N m 4 0 kgf m 29 ft Ib Starter Motor Disassembly e Remove Field Coil Cable Nut A Field Coil Cable B e Remove Starter Motor Through Bolts A Yoke B igit Electric St
362. wer Outlet o DH Parking Brake Hour Meter Radiator Light Fan Switch Breaker x SS BR p i 5 8 AL ALI E E 4 Y R 157 Speedometer lllumination 12V1 7W 011 Pressure Warning Indicator Light 12V1 7W 0 0 Glow Plug Light 12V1 7W BK Y Coolant Temperature Warning BR BR es 1 Parking Brake R Indicator Light 12V3W Indicator Light 12V3W R G BK Y Light BK R Y Switch Y BK BL Y BK Y W BK r H Main Switch sw TEE LLL Ex T i xcu 1 C lt ii W R R BK nec BK Y Headlights gt 7 z 12V35WX2 i m mm 8 r C T R Horn Button o Steering Shaft Component Battery LS 12V52Ah Engine Brake Light BR Ground Switch SEM Terminal BR BK Y Radiator Fan Relay BK Horn O Ei 8kK W Steering Gear Assembly R BK BK Y BK L 8k BR BK BL BL Alternator Radiator Fan Switch i Radiator Fan ir cum BK Y LIGHT SWITCH CONNECTIONS Color 0 Y MAIN SHITCH GONNEGTIONS Color BK YW BKBK W BR For pow oN oo on START omo 42105448845 ELECTRICAL Wiring Diagram KAF950GB GC EPS EGU EPS W gt arning Indicator Light LED 1 Work Lamp 12V55W 2 Socket 3 Back up Beeper 1
363. ystem Diodes Inspection e Remove the diodes see Diodes Removal Installation e Set the hand tester to the x 10 O or x 100 O range and connect it to the diode terminals to check the resistance in both directions Special Tool Hand Tester 57001 1394 he resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the diode unit must be replaced NOTE OThe actual meter reading varies with the meter used and the individual diode but generally speaking the lower reading should be from the zero to one half the scale EPS Fuse 40 A Removal NOTICE Before removing the 40 A fuse A be sure to dis connect the battery cables to avoid electrical shock NOTE OThe EPS fuse 40 is installing with bolts to the EPS fuse box 1 B e Disconnect the battery cables see Battery Removal in the Electrical System chapter e Lift up the EPS fuse box 1 A with rubber protector B e Slide the rubber protector A e Unlock the hooks to open the lids B STEERING 15 57 15 58 STEERING EPS Electric Power Steering System e Remove the terminal bolt A on both sides e Unlock the hook to lift up the lid A e Pull the EPS fuse 40 A B straight out of the EPS fuse box 1 C EPS Fuse 7 5 A Removal e ilt up the front seat e Unlock the hook to lift up the lid A e Pull the EPS fuse 7 5 A
364. ything e Install the water pipes A e Tighten Torque Water Pipe Mounting Bolts B 8 8 N m 0 90 kgf m 78 in lb i XR T P Hose Inspection e Refer to the Radiator Hose and Connection Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 15 Radiator Fan Switch Coolant Temperature Switch Radiator Fan Switch Removal NOTICE The fan switch or the coolant temperature switch should never be allowed to fall on a hard surface Such a shock to their parts can damage them e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the front cover see Front Cover Removal in the Frame chapter e Turn over the rubber cover A e Remove Radiator Fan Switch Lead Connectors B Radiator Fan Switch C Coolant Temperature Switch Removal e ilt up the cargo bed e Remove Coolant Temperature Switch Lead Connector A Coolant Temperature Switch B Radiator Fan Switch Coolant Temperature Switch Installation e Apply grease to the O ring on the fan switch e Apply a non permanent locking agent to the threads of the coolant temperature switch e Tighten the fan switch and coolant temperature switch Torque Radiator Fan Switch 25 2 5 kgf m 18 ft Ib Coolant Temperature Switch 27 2 8 kgfm 20 ft Ib Radiator Fan Switch Inspection e Refer to the Radiator Fan Switch Inspection in the Elec trical System chapter

2009-2013 Kawasaki Mule 4010 Trans Diesel 4x4 Service Manual

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