Mule 3010 Diesel (2003-2007)

MULE 3010
DIESEL
Utility Vehicle
Service Manual
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Cooling System 4 j
Engine Top End 5 j
Converter System 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankshaft/Crankcase 9 j
Transmission 10 j
Wheels/Tires 11 j
Final Drive 12 j
Brakes 13 j
Suspension 14 j
Steering 15 j
Frame 16 j
This quick reference guide will assist

Electrical System 17 j
you in locating a desired topic or pro-
cedure.
Appendix 18 j
•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.
MULE3010
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 Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your dealer for the latest information on
product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2002 Kawasaki Heavy Industries. Ltd., Fifth Edition (1) : Jun. 30, 2006 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pounds(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.

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 compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow
-by gases are led to the breather chamber through the crankcase to the intake 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 atomosphere.
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(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to 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)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser..."
NOTE
○The 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 VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
(United States Model only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective
intake and exhaust silencing systems. They are designed to give optimum performance while
maintaining a low noise level. Please do not remove these systems, or alter them in any way
which results in an increase in noise level.
Foreword
This manual is designed primarily for use by The Quick Reference Guide shows you all
trained mechanics in a properly equipped shop. of the product’s system and assists in locating
However, it contains enough detail and basic in- their chapters. Each chapter in turn has its own
formation to make it useful to the owner who de- comprehensive Table of Contents.
sires to perform his own basic maintenance and For example, if you want ignition coil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Electrical System chapter. Then, use the
dures must be understood in order to carry out Table of Contents on the first page of the chap-
maintenance and repair satisfactorily. When- ter to find the ignition coil section.
ever the owner has insufficient experience or Whenever you see these WARNING and
doubts his ability to do the work, all adjust- CAUTION symbols, heed their instructions!
ments, maintenance, and repair should be car- Always follow safe operating and maintenance
ried out only by qualified mechanics. practices.
In order to perform the work efficiently and
WARNING
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures This warning symbol identifies special
before starting work, and then do the work care- instructions or procedures which, if not
fully in a clean area. Whenever special tools or correctly followed, could result in per-
equipment are specified, do not use makeshift sonal injury, or loss of life.
tools or equipment. Precision measurements
can only be made if the proper instruments are CAUTION
used, and the use of substitute tools may ad-
This caution symbol identifies special
versely affect safe operation.
instructions or procedures which, if not
For the duration of the warranty period,
strictly observed, could result in dam-
we recommend that all repairs and scheduled
age to or destruction of equipment.
maintenance be performed in accordance with
this service manual. Any owner maintenance or This manual contains four more symbols (in
repair procedure not performed in accordance addition to WARNING and CAUTION) which will
with this manual may void the warranty. help you distinguish different types of informa-
To get the longest life out of your vehicle: tion.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled ○This note symbol indicates points of par-
maintenance. ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Vehi- venient operation.
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki • Indicates
done.
a procedural step or work to be
Vehicles are introduced by the Service Man-
ual. Genuine parts provided as spare parts
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
are listed in the Parts Catalog. also precedes the text of a NOTE.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
• Remember to keep complete records of main-
tenance and repair with dates and any new
tion in the procedural step or sub-step it fol-
lows.
parts installed. In most chapters an exploded view illustration
of the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into its instructions indicating which parts require spec-
major systems and these systems make up the ified tightening torque, oil, grease or a locking
manual’s chapters. agent during assembly.
GENERAL INFORMATION 1-1
General Information 1
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-6
Technical Information - Fuel Injection System Components................................................... 1-9
Unit Conversion Table ............................................................................................................ 1-11
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
(1) Dirt
Before removal and disassembly, clean the vehicle. Any dirt entering the engine will shorten the
life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal
filings.
(2) Battery Ground
Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the vehicle. This prevents the engine from accidentally turning over while work is being carried
out, sparks from being generated while disconnecting the cable from electrical parts, as well as
damage to the electrical parts themselves. For reinstallation, first connect the positive cable to
the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if instal-
lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during removal or disassembly so they can be installed or assem-
bled in the same way. It is preferable to mark and record the locations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removing screws held by non-permanent locking
agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
(10)Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam-
age.
Before Servicing
(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally dam-
ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks,
press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re-
moval weakens and deforms them. If old ones are reused, they could become detached while
the vehicle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos-
itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as
well.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed.
Replacement parts will be damaged or lose their original function once they are removed. There-
fore, always replace these parts with new ones every time they are removed. Although the pre-
viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Leads
All the electrical wires are either one-color or two-color. A two-color lead is identified first by
the primary color and then the stripe color. For example, a yellow Lead with thin red stripes is
referred to as a “yellow/red” Lead; it would be a “red/yellow” Lead if the colors were reversed.
Unless instructed otherwise, electrical Leads must be connected to Leads of the same color.
Two-Color Electrical
Before Servicing
(19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20)Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
Model Identification
KAF950-B1 Left Side View
KAF950-B1 Right Side View

General Specifications
Items KAF950-B1 KAF950-B2 ∼, B6F ∼

Dimensions
Overall Length 2 861 mm (112.64 in.)
Overall Width 1 440 mm (56.69 in.)
Overall Height 1 930 mm (75.98 in.)
Wheelbase 1 870 mm (73.62 in.)
Tread:
Front 1 160 mm (45.67 in.)
Rear 1 180 mm (46.46 in.)
Ground Clearance 175 mm (6.89 in.)
Seat Height 875 mm (34.45 in.)
Dry Weight 681 kg (1 502 lb) 683 (1 506 lb)
Curb Weight:
Front 312 kg (688 lb) 313 kg (690 lb)
Rear 400 kg (882 lb) 401 kg (884 lb)
Fuel Tank Capacity 20 L (5.3 US gal)
Cargo Bed (L × W × H) 1 175 × 1 310 × 288 mm (46.26 × 51.57 × 11.34 in.)
Performance
Minimum Turning Radius 3.4 m (11.16 ft)
Engine
4-stroke, OHV, Diesel, 3
Type
cylinder
Cooling System Liquid-cooled
Bore and Stroke 72 × 78 mm (2.83 × 3.07 in.)
Displacement 953 cm³ (58.15 cu in.)
Compression Ratio 24.8
Injection Pump Denso VE type
Starting System Electric starter
Cylinder Numbering Method Right to left, 1-2-3
Firing Order Right to left, 1-2-3
Valve Timing:
Open 10° BTDC

Close 45° ABDC
Duration 235°
Exhaust:
Open 45° BBDC
Close 10° ATDC
Duration 235°
Lubrication System Forced lubrication (wet sump)
Engine oil:
Grade API CF or CF4
Viscosity SAE 10W-40
Capacity 3.3 L (3.5 US qt)

Drive Train
Primary Reduction System:
Type Belt drive torque converter
Reduction Ratio 3.5 ∼ 0.98 3.7 ∼ 0.98
Transmission Gear Ratio:
Forward:
High 1.821 (51/28)
Low 3.750 (51/28 × 25/20 × 28/17)
Reverse:
Low 4.220 (41/20 × 25/20 × 28/17)
Final Drive System:
Type Gear (4WD/2WD)
Reduction Ratio 5.4 (81/15) 5.429 (76/14)
Overall Drive Ratio:
Forward:
High 9.639 9.690
Low 19.845 19.950
Reverse:
Low 22.335 22.454
Front Final Gear Case Oil:
API GL-5 or GL-6 Hypoid gear
Type
oil for LSD
SAE 90, or SAE 140
Transmission Oil:
API GL-5 Hypoid gear oil, SAE
Type
90 (above 5°C, 41°F) or
SAE 80 (below 5°C, 41°F)
Frame
Type Steel tube, Ladder
Caster (rake angle) 7.5°
Camber 0.8°
Trail 35 mm (1.38 in.)
Tire:
Front and Rear 23 × 11.00-10, Tubeless
Rim:
Front and Rear 10 × 8
Steering Type Rack and pinion
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)
Drum (Mechanical internal
Parking Brake Type
expansion)
Electrical Equipment
Battery 12 V 52 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 30 W × 2
Brake/trail Light:
Bulb 12 V 21/5 W × 2
Alternator:
Type Three - phase AC
Rated Output 12 V, 40 A
Load Capacity
Maximum Vehicle Load
(including occupants and cargo) 740 kg (1 631 lb)
Maximum Cargo Bed Load 499 kg (1 100 lb)
Specifications are subject to change without notice, and may not apply to every country.
Technical Information - Fuel Injection System Components
The fuel system consists of a gear driven injection pump with fuel delivery and return lines and an
injection nozzle for each cylinder. Diesel fuel is drawn from the fuel tank through the fuel filter by the
feed pump which is incorporated in the injection pump and delivers fuel to the injection nozzles at a
constant volume regardless of pump RPM. The feed pump also circulates fuel through the pump for
lubrication purposes.
A single pump plunger meters and distributes fuel in the correct firing order through an injection
nozzle in each combustion chamber. Excess fuel from the injection nozzles and pump is returned to
the fuel tank by way of the overflow screw and return line. This system of fuel circulation lubricates
and cools the injection pump and also warms the fuel in the fuel tank to help prevent fuel waxing in
cold weather.
CAUTION
Always use clean fresh diesel fuel with a minimum of 40 cetane (ASTM D975). DO NOT use
kerosene. The injection pump requires diesel fuel for lubrication. Damage to the injection
pump and/or engine may result if kerosene is used.
Technical Information - Fuel Injection System Components
1. Fuel Tank
2. Fuel Filter
3. Injection Pump
4. Injection Nozzles
5. Fuel Line
6. Fuel Delivery Line
7. Fuel Return Line
Unit Conversion Table
Prefixes for Units Units of Length
km × 0.6214 = mile
Prefix Symbol Power m × 3.281 = ft
mega M × 1 000 000 mm × 0.03937 = in
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque
micro µ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
Units of Mass
kgf·m × 86.80 = in·lb
kg × 2.205 = lb
g × 0.03527 = oz
Units of Pressure
kPa × 0.01020 = kgf/cm²
Units of Volume kPa × 0.1450 = psi
L × 0.2642 = gal (US) kPa × 0.7501 = cmHg
L × 0.2200 = gal (imp) kgf/cm² × 98.07 = kPa
L × 1.057 = qt (US) kgf/cm² × 14.22 = psi
L × 0.8799 = qt (imp) cmHg × 1.333 = kPa
L × 2.113 = pint (US)
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
Units of Speed
mL × 0.02816 = oz (imp)
km/h × 0.6214 = mph
mL × 0.06102 = cu in
Units of Force Units of Power

N × 0.1020 = kg kW × 1.360 = PS
kW × 1.341 = HP
N × 0.2248 = lb
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP
Units of Temperature
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
2
Periodic Maintenance Chart .............. 2-2 Transmission .................................. 2-27

Torque and Locking Agent................. 2-4 Transmission Oil Change............. 2-27
Specifications .................................... 2-9 Final Drive....................................... 2-28
Special Tools ..................................... 2-11 Front Final Gear Case Oil
Periodic Maintenance Procedures..... 2-12 Change...................................... 2-28
Fuel System.................................... 2-12 Wheels/Tires ................................... 2-28
Throttle Pedal Free Play Wheels Nuts Tightness
Inspection.................................. 2-12 Inspection.................................. 2-28
Idle Speed Inspection .................. 2-12 Tire Wear Inspection .................... 2-29
Fuel Hoses and Connections Brakes............................................. 2-29
Inspection.................................. 2-13 Brake Fluid Level Inspection........ 2-29
Fuel Hoses Replacement............. 2-13 Brake Fluid Change ..................... 2-30
Fuel Filter Element Replacement. 2-14 Brake Pedal Play Inspection ........ 2-31
Fuel Filter Water Draining ............ 2-15 Brake Master Cylinder Cup and
Cooling System............................... 2-15 Dust Cover Replacement .......... 2-32
Coolant Change ........................... 2-15 Brake Hose and Pipe Inspection.. 2-32
Radiator Cleaning ........................ 2-18 Brake Hose and Pipe
Radiator Hose and Connection Replacement ............................. 2-33
Inspection.................................. 2-18 Brake Wear Inspection................. 2-34
Cooling Fan Belt Inspection ......... 2-19 Brake Wheel Cylinder Assembly
Engine Top End .............................. 2-20 Replacement ............................. 2-35
Valve Clearance Inspection ......... 2-20 Parking Brake Lever Inspection ... 2-37
Valve Clearance Adjustment........ 2-21 Steering .......................................... 2-39
Spark Arrester Cleaning............... 2-22 Steering Inspection ...................... 2-39
Converter System ........................... 2-22 Steering Joint Dust Boot
Converter Air Cleaner Element Inspection.................................. 2-39
Cleaning/Inspection................... 2-22 Frame ............................................. 2-39
Converter Drive Belt Inspection ... 2-23 Seat Belt Inspection ..................... 2-39
Converter Drive Belt Deflection Electrical System ............................ 2-40
Inspection (KAF950-B2 ∼, B6F) 2-24 Electrolyte Level Inspection
Converter Drive Belt Deflection (Conventional Type Battery)...... 2-40
Adjustment (KAF950-B2 ∼, B6F Electrolyte Specific Gravity
∼) ............................................... 2-24 Inspection (Conventional Type
Converter Driven Pulley Shoe Battery)...................................... 2-41
Inspection.................................. 2-25 Charging Condition Inspection
Engine Lubrication System ............. 2-26 (Conventional Type Battery)...... 2-42
Engine Oil and/or Oil Filter Brake Light Switch Inspection...... 2-42
Change...................................... 2-26 General Lubrication ........................ 2-43
Oil Filter Removal ........................ 2-27 Bolts, Nuts, and Fasteners ............. 2-44
Oil Filter Installation ..................... 2-27 Tightness Inspection .................... 2-44
2-2 PERIODIC MAINTENANCE
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.
Whichever
First
FREQUENCY comes Regular Service
Service
first
→ After Every Every Every Every See
50 h, or 100 h, 250 h, 500 h, 800 h, Page
1 000 or or or or
km 2 000 5 000 10 000 16 000
↓ of use km km km km
OPERATION Every of use of use of use of use
ENGINE
Throttle pedal play - inspect • • 2-12
Idle speed - adjust • • 2-12
Fuel hoses and connections -
inspect* • • 2-13
Fuel hose - replace 4 years 2-13

Fuel filter element - replace* • 2-14
Fuel filter water - drain* • 2-15
Coolant - change 2 years 2-15
Radiators - clean* • • 2-18
Radiator hoses and
connections -inspect*
1 year • • 2-18
Cooling fan belt - inspect • 2-19

Valve clearance - inspect • 2-20
Spark arrester - clean • 2-22
Converter air cleaner element
- clean* • • 2-22
Converter drive belt - inspect* • 2-23

Converter drive belt deflection
- inspect* (KAF950-B2 ∼) • 2-24
Converter drive belt deflection

- adjust* (KAF950-B2 ∼) • 2-24
Converter driven pulley shoe

-inspect* • 2-25
Engine oil - change* 1 year • • 2-26

Oil filter - replace* • • 2-26
•: Clean, adjust, lubricate, torque, or replace parts as necessary.

*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
Periodic Maintenance Chart
Whichever
First
FREQUENCY comes Regular Service
Service
first
→ After Every Every Every Every See
50 h, or 100 h, 250 h, 500 h, 800 h, Page
1 000 km or or or or
of use 2 000 5 000 10 000 16 000
↓ km km km km
OPERATION Every of use of use of use of use
CHASSIS
Front final gear case oil and 2-27
transmission oil - change*
1 year • • 2-28
Wheel nuts tightness - inspect • • 2-28
Tire wear - inspect* • • 2-29
Brake fluid level - inspect • • 2-29
Brake fluid - change 2 years 2-30
Brake pedal play - inspect* • • 2-31
Brake master cylinder cup and
2 years 2-32
dust cover - replace
Brake hose and pipe - inspect • • 2-32
Brake hose - replace 4 years 2-33
Brake wear - inspect* • 2-34
Brake wheel cylinder assembly
2 years 2-35
-replace
Parking brake lever - inspect • • 2-37
Steering - inspect • • 2-39
Steering joint dust boots - inspect • • 2-39
Seat belt - inspect • 2-39
Battery - inspect • 2-40
Brake light switch - inspect • • 2-42
General lubrication - perform* • 2-43
Bolts, nuts, and fasteners
tightness - inspect • • 2-44
•: Clean, adjust, lubricate, torque, or replace parts as necessary.

*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of
a non-permanent locking agent or liquid gasket.
L: Apply a non-permanent locking agent to the threads.

MO: Apply molybdenum disulfide oil (the weight ratio of the mixture between engine oil and disulfide
grease is 10 : 1).
O: Apply an oil to the threads, seated surface, or washer.
S: Tighten the fasteners following the specified sequence.
SS: Apply a silicone sealant to the threads.
LG: Apply liquid gasket (Three Bond: 1207F).
Torque Re-
Fastener
N·m kgf·m ft·lb marks
Fuel System
Fuel Injection Nozzles 59 6.0 43
Linkage Pipe Nuts 27 2.8 20
Idle Adjusting Screw Locknut 5.6 0.57 50 in·lb
Maximum Speed Set Screw Locknut 6.9 0.70 61 in·lb
Fuel Injection Pipe Mounting Nuts 25 2.5 18
Fuel Injection Pipe Clamp Bolts 7.4 0.75 65 in·lb
Distributor Head Bolt 17 1.7 12
Fuel Injection Pump Mounting Nuts 20 2.0 14
Fuel Injection Pump Bracket Bolts 20 2.0 14
Fuel Filter Mounting Bolts 20 2.0 14
Air Vent Plug 4.9 0.50 43 in·lb
Cooling System
Water pump mounting bolts and nuts 20 2.0 14
Coolant inlet bolts 7.8 0.80 69 in·lb
Fan mounting bolts 8.8 0.90 78 in·lb
Thermostat housing cap bolts 7.8 0.80 69 in·lb
Radiator fan switch 25 2.5 18
Radiator mounting bolts 8.8 0.90 78 in·lb
Radiator screen bolts 8.8 0.90 78 in·lb
Coolant reservoir tank bolts 4.5 0.45 40 in·lb
Coolant drain plug 25 2.5 18 L
Water temperature warning light switch 27 2.8 20 L
Thermostat housing cap plug – – – L
Engine Top End
Cylinder Head Bolts 34 3.5 25 O, S
Cylinder Head Cover Nuts 5.4 0.55 48 in·lb
Rocker Arm Components Mounting Nuts 20 2.0 14
Valve Adjusting Screw Locknuts 11 1.1 95 in·lb
Inlet Manifold Mounting Bolts and Nuts 7.8 0.80 69 in·lb
Exhaust Manifold Mounting Nuts 20 2.0 14
Muffler Mounting Bolts – – – L
Water Pump Mounting Studs – – – L
Torque Re-
Fastener
Converter System
Drive Pulley Bolt 93 9.5 69
Driven Pulley Bolt 93 9.5 69 L
Converter Cover Bolts 4.4 0.45 39 in·lb
Converter Case Bolts (L = 55 mm) and Nut 27 2.8 20 L
Converter Case Bolts (L = 28 mm) 20 2.0 14 L
Drive Pulley Cover Bolts 13 1.3 110 in·lb
Converter Fan Cover Bolts 8.8 0.9 87 in·lb
Driven Pulley Coupling Bolts 13 1.3 110 in·lb
Weight Holder Bolts 13 1.3 110 in·lb
Roller Holder Bolts 13 1.3 110 in·lb
Inner Cover Bolts 4.4 0.45 39 in·lb
Spider (KAF950-B2 ∼, B6F ∼) 275 28 203 Lh
Wear Shoe Mounting Screws (KAF950-B2 ∼, B6F ∼) 1.1 0.11 10 in·lb L
Ramp Weight Nuts (KAF950-B2, B6F ∼) 6.9 0.70 61 in·lb
Ramp Weight Collar Bolts 7.8 0.80 69 in·lb L
Engine Lubrication System
Engine Oil Drain Plugs 34 3.5 25
Oil Strainer Mounting Bolts and Nuts 7.8 0.80 69 in·lb
Oil Pan Bolts and Nuts 7.8 0.80 69 in·lb
Relief Valve Bolt 39 4.0 29
Oil Pressure Switch 14 1.4 10 SS
Oil Filter Stud Bolt 44 4.5 33
Oil Pump Gear Bolt 20 2.0 14
Oil Nozzle 9.8 ∼ 18 1.0 ∼ 1.8 7.2 ∼ 13
Engine Removal/Installation
Stay Rod Rear Bolt 88 9.0 65
Engine Bracket Bolts – – – L
Engine Mounting Bolts 44 4.5 33
Crankshaft/Crankcase
Camshaft Retainer Bolts 7.8 0.80 69 in·lb
Timing Gear Case Bolts 7.8 0.80 69 in·lb
Idle Gear Bolts 25 2.6 19
Fuel Injection Pump Gear Nut 64 6.5 47
Camshaft Gear Bolt 43 4.4 32
Oil Pump Gear Bolt 20 2.0 14
Oil Nozzle 9.8 ∼ 18 1.0 ∼ 1.8 7.2 ∼ 13
Timing Gear Case Cover Bolts and Nuts 7.8 0.80 69 in·lb
Crankshaft Pulley Bolt 98 10 72 O
Connecting Rod Cap Nuts 36 3.7 27
Crankshaft Main Bearing Cap Bolts 59 6.0 43
Oil Seal Retainer Bolts 5.4 0.55 48 in·lb
End Plate Bolt 39 4.0 29
Torque Re-
Fastener
Flywheel Mounting Bolts (KAF950-B1) 44 4.5 33 LG
Flywheel with Coupling Mounting Bolts (KAF950-B2 44 4.5 33
∼, B6F ∼)
Coupling Bolts (KAF950-B1) 37 3.8 27 L
Crankcase Plug 25 2.5 18 L
End Plate Seal Cover Bolts – – – LG
End Plate Seal Cover Studs – – – LG
Transmission
Transmission Oil Drain Plug 15 1.5 11
Transmission Case Mounting Bolts 44 4.5 33
Transmission Case Bolts 8.8 0.90 78 in·lb
Shift Arm Positioning Bolt 37 3.8 27
Hi/Low Gear Case Bolts 20 2.0 14
Shift Shaft Stop Bolt 7.8 0.80 69 in·lb
Differential Gear Housing Bolts (KAF950-B1) 29 3.0 22 L
Differential Gear Housing Bolts (KAF950-B2 ∼, B6F
57 5.8 42 L
∼)
Bearing Holder 120 12 87
Neutral Switch 15 1.5 11
Wheels/Tires
Tie-Rod End Locknuts 49 5.0 36
Wheel Nuts 140 14 100
Final Drive
Oil Filler Cap 29 3.0 22
Oil Drain Plug 20 2.0 14
Gear Case Bracket Bolts 44 4.5 33
Gear Case Mounting Nuts 44 4.5 33
Ring Gear Cover Bolts (10 mm) 47 4.8 35
Ring Gear Cover Bolts (8 mm) 25 2.5 18
Pinion Gear Bearing Housing Nuts 25 2.5 18
Differential Case Torx Bolts 32 3.3 24 L
Ring Gear Bolts 49 5.0 36
Pinion Gear Slotted Nut 120 12 87 MO
Bevel Gear Case Bolts 22 2.2 16
Driven Gear Shaft Nut 110 11 80 L
Bearing Holder 120 12 87 L
Housing Locknut 120 12 87 L
Bevel Gear Case Holder Nuts 25 2.5 18
Drive Gear Nut 120 12 87 MO
Drive Shaft Cap Bolts 8.8 0.90 78 in·lb
Brakes
Bleed Valves 5.9 0.60 52 in·lb
Push Rod Locknut 18 1.8 13 cylinder
Torque Re-
Fastener
Brake Hose Banjo Bolts 25 2.5 18
Brake Pipe Nipples 18 1.8 13
Piston Stop Bolt 8.8 0.90 78 in·lb cylinder
Master Cylinder Reservoir Cap 3.4 0.35 30 in·lb
Reservoir Clamp Bolt 5.9 0.60 52 in·lb
Front Axle Nut 200 20 140
Rear Axle Nut 300 31 220
Wheel Cylinder Mounting Bolts 11 1.1 95 in·lb front
Wheel Cylinder Mounting Nuts 7.8 0.80 69 in·lb rear
Brake Panel Mounting Bolts 44 4.5 33 L
Suspension
Strut Mounting Nuts 44 4.5 33
Strut Clamp Nut 98 10 72
Rear Shock Absorber Mounting Nuts 59 6.0 43
Strut Locknut 49 5.0 36
Front Suspension Arm Pivot Bolts 98 10 72
Front Suspension Arm Joint Nut 78 8.0 58
Damper Bracket Mounting Nuts 44 4.5 33
Leaf Spring Mounting Nuts (Front) 98 10 72
Leaf Spring Mounting Nuts (Rear) 59 6.0 43
Steering
Steering Wheel Mounting Nut 52 5.3 38
Intermediate Shaft Clamp Bolts 20 2.0 14
Steering Gear Assembly Bracket Bolts 52 5.3 38 L
Tie-Rod End Nuts 34 3.5 25
Rack Guide Spring Cap Locknut 39 4.0 29
Tie-Rod End Locknuts 49 5.0 36
Strut Clamp Nut 98 10 72
Frame
Battery Holder Mounting Nut 17 1.7 12
Stay Rod Rear Bolt 88 9.0 65
Seat Belt Mounting Bolts 34 3.5 25
Front Bar Mounting Bolts (Lower) 98 10 72
Front Bar Mounting Bolts (Upper) 44 4.5 33
Rear Bar Mounting Bolts and Nuts (Lower) 44 4.5 33
Rear End Sub-Frame Mounting Nuts 44 4.5 33
Latch Handle 4.4 0.45 39
Electrical System
Alternator Adjusting Bracket Bolts 20 2.0 14
Alternator Mounting Bolt 39 4.0 29
Alternator Pulley Locknut 11 1.1 95 in·lb
Starter Motor Mounting Bolts 39 4.0 29
Starter Motor End Cover Screws 1.5 0.15 13 in·lb
Torque Re-
Fastener
Starter Motor Through Bolts 9.3 0.95 82 in·lb
Glow Plugs 17 1.7 12
Connecting Plate Nuts 1.2 0.12 10 in·lb
Oil Pressure Switch 14 1.4 10 SS
Neutral Switch 15 1.5 11
Radiator Fan Switches 25 2.5 18
Water Temperature Warning Light Switch 27 2.8 20 L
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 dia. Mark of Torque
(mm) bolt head N·m kgf·m ft·lb
6 4T 3.9 ∼ 4.9 0.40 ∼ 0.50 35 ∼ 43 in·lb
6 7T 7.8 ∼ 9.8 0.80 ∼ 1.0 69 ∼ 87 in·lb
6 9T 12 ∼ 15 1.2 ∼ 1.5 104 ∼ 130 in·lb
8 4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 120 in·lb
8 7T 18 ∼ 22 1.8 ∼ 2.2 13 ∼ 16
10 4T 20 ∼ 24 2.0 ∼ 2.4 14 ∼ 17
10 7T 39 ∼ 44 4.0 ∼ 4.5 29 ∼ 33
Basic Torque for General Fasteners of Frame Parts

Threads dia. Torque
(mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.8 ∼ 7.9 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 14
10 26 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
Specifications
Item Standard Service Limit

Fuel System
Throttle Pedal Free Play 5 ∼ 10 mm (0.2 ∼ 0.39 in.) – – –
Idle Speed 850 ∼ 950 r/min (rpm) – – –
Cooling System
Coolant:
Type Permanent type of antifreeze – – –
(Soft water and ethylene glycol plus
corrosion and rust inhibitor chemicals
for aluminum engine and radiators)
Color Green – – –
Mixed Ratio Soft water 50% × coolant 50% – – –
Freezing Point –35°C (–31°F) – – –
Total Amount 4.6 L (4.9 US qt) – – –
9.5 ∼ 11.5 mm (0.37 ∼ 0.45 in) @98 N (10
Fan Belt Deflection – – –
kgf, 22 lb)
Engine Top End
Valve Clearance (when cold) 0.2 mm (0.0079 in.) –––
Converter System
Belt Width 31.5 mm (1.24 in.) (KAF950-B1), 30.0 mm (1.18 in.)
34.1 mm (1.34 in.) (KAF950-B2 ∼, B6F ∼), 32.6 mm (1.28 in.)
Belt Deflection 28 ∼ 36 mm (1.10 ∼ 1.42 in.) (KAF950-B2
– – –
∼, B6F ∼)
Wear Shoe Width ––– 11 mm (0.43 in.)
(KAF950-B1)
––– 16.4 mm (0.65 in.)
(KAF950-B2 ∼,
B6F ∼)
Engine Ooil:
Grade API CF or CF-4 class – – –
Viscosity SAE 10W-40 – – –
Capacity 3 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 Oil:
Type API "GL-5" 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) – – –
Oil Level Between upper and lower level lines – – –
Wheels/Tires
Tire Tread Depth 13.2 mm (0.520 in.) 3 mm (0.12 in.)
Specifications

Final Drive
Front Final Gear Case Oil: – – –
Type API "GL-5 or GL-6" hypoid gear oil for LSD
(Limited Slip Differential gears)
Viscosity SAE 90 or SAE 140 – – –
Oil level Filler opening level – – –
Brakes
Brake Fluid:
Grade DOT3 – – –
Fluid Level Between upper and lower level lines – – –
Brake Pedal Play 2 ∼ 10 mm (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 N (20 kgf, 44 lb)
Steering
Steering Wheel Free Play 0 ∼ 20 mm (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 (see text) – – –
Specific Gravity 1.265 @20° (68°F) – – –
Switches:
Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel – – –
Special Tools
Inside Circlip Pliers: Brake Drum Pusher, M18 × 1.5:
57001-143 57001-1261
Rotor Puller, M16/M18/M20/M22 × 1.5: Brake Drum Holder:

57001-1216 57001-1325
Brake Drum Remover: Brake Drum Remover Nuts:

57001-1260 57001-1326
Periodic Maintenance Procedures
Fuel System
Throttle Pedal Free Play Inspection
• Check that the throttle pedal moves smoothly from full
open to close.
If the throttle pedal does not return properly, lubricate the
throttle cable and link (see Fuel System chapter).
• Check the throttle pedal free play [A].
Throttle Pedal Free Play
Standard: 5 ~ 10 mm (0.2 ~ 0.4 in.)
If the free play is incorrect, adjust the throttle cable.
• Tilt up the cargo bed.

• of the cable.
Loosen the adjuster mounting nuts [A] at the engine end
• Slide the adjuster [B] until the proper amount of throttle

pedal free play is obtained.
• Tighten the mounting nuts securely.
• With the transmission
Start the engine.
• a few times to make insure
neutral, operate the throttle pedal
that the idle speed does not
change.
If the idle speed does change, the throttle cable may be
improperly adjusted, incorrectly routed, or it may be dam-
aged.
• Correct any of these conditions before operation.
WARNING
Operation with improperly adjusted, incorrectly
routed, or a damaged cable could result in an un-
safe operating condition.
NOTE
○If the throttle pedal free play cannot be adjusted by us-
ing the adjuster at the engine end of the cable, use the
cable adjuster [A] at the throttle pedal. Do not forget to
securely tighten the adjuster mounting nuts [B].
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• Check the
Tilt up cargo bed.
• Tachometer
the idle speed with a suitable tachometer [A].
Adapter [B]
Idle Speed
Standard: 850 ~ 950 r/min (rpm)
If the idle speed is out of the specified range, adjust it.
• Remove:
Injection Pump Cover Bolts [A]
Injection Pump Cover [B] (only)
○Retighten the bolts with bracket [C].

• Turn thethe
Loosen locknut [A].
• the idle speedadjusting
idle screw [B] at the injection pump until
is correct.
• Tighten:
Torque - Idle Adjusting Screw Locknut: 5.6 N·m (0.57
kgf·m, 50 in·lb)
• 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
• Lift up the cargo bed and seat.
• and signs
Check the fuel hoses and fittings for deterioration, cracks
of leakage.
Replace the fuel hose if any fraying, leak [A], cracks [B]
or bulges [C] are noticed.
• Check that the hoses are securely connected and clamps
are installed correctly.
• When installing, route the hoses according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
• 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.
Replace the hose if it has been sharply bent or kinked.
Fuel Hoses Replacement
• Tilt up the cargo bed and seat.
• Remove
Slide out the plate clamps [A].
• chapter).the hoses [B] (see Exploded View in Fuel System
• When installing, route the hoses according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
• 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.
• Fit the fuel hose [A] onto the fitting fully and install the
plate clamp [B] beyond the raised rib [C].
1 ~ 2 mm (0.0039 ~ 0.0078 in.) [D]
○The hose end must reach the filler [E] or be as near as
possible to the step [F].
• Bleed the air from the fuel filter (see Next Section).
Fuel Filter Element Replacement
• Tilt up the seat.
• Remove:
Fuel Hoses [A]
Fuel Filter Mounting Bolts [B]
Fuel Filter [C]
• Remove:
Drain Cap [A]
O-ring [B]
Filter Cartridge [C]
○Use a suitable filter wrench.
•Install a new filter cartridge by hand until the gasket con-
tacts the housing. Then tighten it 1/3 turn more.
•Install:
Drain Cap
New O-ring
Fuel Filter
Fuel Hoses
•Tighten:
Torque - Fuel Filter Mounting Bolts: 20 N·m (2.0 kgf·m, 14
ft·lb)
•○Bleed the air from the fuel filter.

Loosen the air vent plug [A].
○Pump the priming button [B] until the fuel comes out of
the air vent.
○Tighten the air vent plug securely.
Torque - Air Vent Plug: 4.9 N·m (0.50 kgf·m, 43 in·lb)
○Wipe off any spilled fuel.
• Start the engine, and check for fuel leakage.
Fuel Filter Water Draining
• Loosen:a suitable container under the filter drain hose [A].
Place
• Air Vent Plug [B]
• Loosen the drain cap [C] approximately 1 turn, and drain
water from the filter until only fuel flows from the filter.
• Tighten the drain cap securely.
• Replacement).
Bleed the air from the fuel filter (see Fuel Filter Element
○Wipe off any spilled fuel.

Cooling System
Coolant Change
WARNING
To avoid burns, do not remove the radiator caps
or try to change the coolant when the engine is
still hot. Wait until it cools down. Coolant on tires
will make them slippery and can cause an accident
and injury. Immediately wash away any coolant that
spills on the frame, engine, or wheels.
Since coolant is harmful to the human body, do not
use for drinking.
• Tilt up the cargo hood.

• the cap counterclockwise
Remove the front radiator cap [A] in two steps. First turn
to the first stop. Then push and
turn it further in the same direction and remove the cap.
• Pull off the reservoir tank hose [B] and pour the coolant
into a container.

• movethe
Turn
it.
rear radiator cap [A] counterclockwise and re-
• Remove:
Front Final Gear Case Skid Plate [A] (see Final Drive
chapter)
Coolant Drain Plugs [B] at Water Pipes
○Place a container under the drain plugs.
• Tighten the drain plugs.

• Lift the frontreservoir
Install the tank hose.
• ground so that the front
wheels 20 ∼ 30 cm (7.9 ∼ 11.8 in.) from the
radiator cap [A] is the highest port
of the system.
• Pour the coolant slowly into the front radiator cap fitting.
NOTE
○Pour in the coolant slowly so that the air in the engine
and radiators can escape.
Front Radiator Cap [A] Reservoir Tank Cap [C]

Rear Radiator Cap [B] Air Bleeder Bolts [D]
CAUTION
Soft or distilled water must be used with antifreeze
(see Specifications in this chapter) 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°C (–31°F)
Total Amount: 4.6 L (4.9 US qt)
NOTE
○Choose a suitable mixture ratio by referring to the
coolant manufacturer’s directions.
• When the coolant begins to flow out the rear radiator cap
[B] fitting, install the rear radiator cap.
• When the coolant begins to flow out the air bleeder bolt
holes, tighten the air bleeder bolts [D].
• Fill the cooling system up to the filler neck [A] in the front
radiator cap fitting with coolant.
•○Bleed the air from the cooling system as follows.

Start the engine and run it until no more air bubbles [A]
can be seen in the coolant (less than five minutes).
○Tap the radiator hoses to force any air bubbles caught
inside.
○Stop the engine and add coolant up to the filler neck.
•Install the front radiator cap.
•Lower the front wheels slowly.
• Fill the reservoir tank up to the F (Full) level line [A] with
coolant.
CAUTION
Do not add more coolant above the FULL level line.
• Install the reservoir tank cap.
Radiator Cleaning
CAUTION
Clean the radiator screens and the radiators in
accordance 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 screens
and the radiators should be cleaned immediately.
• Remove:
Front Cover (for Front Radiator)
Rear Radiator (see Cooling System chapter).
Radiator Screen Mounting Screws [A]
Radiator Screen [B]
• Clean the radiator screen in a bath of tap water, and then
dry it with compressed air or by shaking it.
CAUTION
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 [B]
from the radiator core.
Hold the steam gun perpendicular to the core sur-
face.
Run the steam gun following the core fin direction.
Radiator Hose and Connection Inspection

○The 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 deterioration. 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.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Cooling Fan Belt Inspection
• Remove the bracket mounting screw [A].
• Remove:
Bracket Mounting Bolts [A]
Bracket [B]
• Remove the propeller shaft bearing housing mounting

bolts [A] and nuts [A].
•○Remove the propeller shaft [B].
Move the propeller shaft bearing housing [C] to the out-
side [D].

• Water Pipe Bolts [A]
Remove:
Fan Cover Bolts (four bolts)

Fan Cover [B]
• Remove:
Fan Mounting Bolts [A]
Fan [B]
Spacer [C]
Fan Belt Cover Mounting Bolts [D]
Fan Belt Cover [E]
• Reinstall
[B].
the spacer [A] and tighten the fan mounting bolts
Torque - Fan Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Check the cooling fan belt [C] for excessive wear crack or
broken.
If necessary, replace the belt with a new one.
•○Check the fan belt deflection.

Use a ruler [A], push the belt with 10 kg (22 lb) force.
Push Gauge [B]
Fan Belt Deflection
Standard: 9.5 ∼ 11.5 mm/10 kgf (22 lb)
If the deflection is incorrect, adjust it.
• Loosen the alternator adjusting bracket bolt [A] and alter-

nator mounting bolt [B].
Alternator [C]
•Adjust the fan belt deflection.
○Use a ruler, push the belt with 10 kg (22 lb) force.
•Tighten the bolts.
Torque - Alternator Adjusting Bracket Bolts: 20 N·m (2.0
kgf·m, 14 ft·lb)
Alternator Mounting Bolt: 39 N·m (4.0 kgf·m, 29
ft·lb)
• Install the removed parts.
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked when the engine is
cold (at room temperature).
• Remove:
Fan Belt Cover (see Cooling Fan Belt Inspection in the
Periodic Maintenance chapter)
Breather Hose [A]
Cylinder Head Cover Mounting Bolts [B]
Washers [C]
Cylinder Head Cover [D]
• 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.
○Check that the rocker arms at #1 cylinder are free.
If not, turn the pulley one more turn to free the rocker
arms.
• Using a thickness gauge [A], measure the valve clearance

between the rocker arm [B] and the valve stem cap [C].
If the valve clearance is incorrect, adjust it.
Valve Clearance (when cold)
Standard: 0.2 mm (0.0079 in.)
○When positioning #1 piston TDC at the compression

stroke:
Inlet valve clearance of #1 and #3 cylinders
Exhaust valve clearance of #1 and #2 cylinders
○Turn the crankshaft pulley 360° clockwise.

Inlet valve clearance of #2 cylinder
Exhaust valve clearance of #3 cylinder
Valve Clearance Adjustment

• Loosen the valve adjusting screw locknut [A].
• Turn the valve adjusting screw [B] until the correct clear-
ance is obtained.
• Holding the adjusting screw, tighten the locknut.
Torque - Valve Adjusting Screw Locknuts: 11 N·m (1.1
kgf·m, 95 in·lb)
Spark Arrester Cleaning
WARNING
To avoid burns, wear gloves while cleaning the
spark arrester. Since the engine must be run dur-
ing this procedure, the muffler will become hot.
• Remove the drain plug [A] from the muffler [B].

• In an openparking
Apply the brake.
• the engine with the gearfrom
area away combustible materials, start
shift lever in the N (neutral) po-
sition.
• Raise and lower engine speed while tapping on the muf-
fler with a rubber mallet until the carbon particles are
purged from the muffler.
WARNING
Do not run the engine in a closed area. Exhaust
gases contain carbon monoxide; a colorless, odor-
less, poisonous gas. Breathing exhaust gas can
lead to carbon monoxide poisoning, asphyxiation,
and death.
• Stop the engine.

• Install the drain plug.
Converter System
Converter Air Cleaner Element Cleaning/Inspection
NOTE
○In dusty areas, the element should be cleaned more
frequently than the recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
WARNING
Clean the element in a well-ventilated area, and take
ample care that there are no sparks or flame any-
where near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or a low flash-point solvent to
clean element.
• Remove
chapter).
the air cleaner element (see Converter System
• Separate
[B].
the foam element [A] from the paper element
• Clean the foam element in a bath of a high flash-point

solvent, and then dry it with compressed air or by shaking
it.
• After cleaning, saturate the foam element with SE class
SAE30 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.
• Clean the paper element by tapping gently.
CAUTION
Do not use compressed air to clean the paper ele-
ment.
Do not oil the paper element.
Converter Drive Belt Inspection

• Remove the driver belt (see Converter System chapter).
• If any measurements
Measure the width [A] of the belt.
exceed the service limit, replace the
belt.
Belt Width
KAF950-B1 KAF950-B2 ∼, B6F ∼
Standard: 31.5 mm (1.24 in.) 34.1 mm (1.34 in.)
Service Limit: 30.0 mm (1.18 in.) 32.6 mm (1.28 in.)
• Check the belt for wear, cracks, breaks or peeling.

If necessary, replace the belt with a new one.
Belt [A]
Crack [B]
Broken [C]
NOTE
○Whenever the belt is replaced, inspect the drive and the
driven pulleys.
Converter Drive Belt Deflection Inspection
(KAF950-B2 ∼, B6F)
• Remove the torque converter cover (see Converter Sys-
tem chapter).
• Put the 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.
•Measure the belt deflection as shown:
○Place a straightedge [A] on top of the belt between the
drive pulley [B] and the driven pulley [C].
○Use a ruler to push the belt away from the straightedge.
Push hard, but with no more force than 59 N (6 kgf, 13 lb).
Belt Deflection
Standard: 28 ∼ 36 mm (1.10 ∼ 1.42 in.)
If 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.
• 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.
Converter Drive Belt Deflection Adjustment
(KAF950-B2 ∼, B6F ∼)
• Disassemble
chapter).
the driven pulley [B] (see Converter System
If the belt deflection is more than 36 mm (1.42 in.), remove

the spacers to decrease it.
○The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer
thickness equals about 1.4 mm (0.055 in.) change in belt
deflection.
If the belt deflection is less than 28 mm (1.10 in.), add the
spacers [A] to increase it.
○The 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.
Spacers
Part No. Thickness
92026-1625 1.0 mm (0.039 in.)
92026-1626 0.6 mm (0.024 in.)
92026-1627 1.4 mm (0.055 in.)
92026-1628 0.8 mm (0.031 in.)
92026-0036 0.3 mm (0.012 in.)
• Assemble
ter).
the driven pulley (see Converter System chap-
• 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.
• Measure the belt deflection again and repeat the above
procedures until it is within the standard range.
• Using a suitable holder, adapter a non-permanent locking
agent to the driven bolt and tighten it.
Torque - Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
Converter Driven Pulley Shoe Inspection
• Remove
ter).
the driven pulley (see Converter System chap-
• Disassemble
chapter).
the driven pulley (see Converter System
If the ramps [A] or the wear shoes [B] are damaged or

worn, replace the ramp cap [C] or the shoes. (KAF950
-B1)
IF the cam [A] of ramp [B] or the wear shoes [C] are
damaged or worn, replace the ramp or the wear shoes.
(KAF950-B2)
If the wear shoe contact area width [A] is greater than the
service limit, replace the shoe [B].
Wear Shoe Width (KAF950-B1)
Service Limit: 11 mm (0.43 in.)
Wear Shoe Width (KAF950-B2 ∼, B6F ∼)
Service Limit: 16.4 mm (0.65 in.)
Engine Oil and/or Oil Filter Change
• Warm up the engine so that the oil will pick up any sedi-
ment and drain easily.
• Place an oil pan beneath the engine.
• Remove the engine oil drain plug [A], and let the oil drain
completely.
If the oil filter is to be changed, replace it with a new one
(See Oil Filter Removal/Installation).
• Check the gasket at the drain plug for damage.
Replace the gasket with a new one.
• After the oil has completely drained out, install the drain
plug with the gasket.
Torque - Engine Oil Drain Plug: 34 N·m (3.5 kgf·m, 25 ft·lb)
CAUTION
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
intake manifold. Oil in the intake manifold may flow
into the combustion chambers and cause hydraulic
lock, resulting in severe engine damage.
• 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.
• Slowly and evenly fill the engine with a good quality oil as
specified in the table.
• Check the oil level.
Engine Oil
Grade: API CF or CF-4 class
Viscosity: SAE 10W-40
Capacity: 3 L (3.2 US qt )
(when filter is not removed)
3.3 L
(when filter is removed)
Oil Level: Between F and L marks on dipstick
NOTE
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
Oil Filter Removal
•○When unscrewing
Remove the oil filter [A] from under the vehicle.
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

• Apply engine oil:
Oil Filter Gasket
•○Install a new filter.
Screw the filter in until the gasket touches the engine, then
turn it 1 turn.
• Add the engine oil (see Oil Level Inspection).
• Thoroughly warm up the engine, and check for oil leakage
and the oil level.
If necessary, add more engine oil.
Transmission
Transmission Oil Change
• Warm up the oil by running the vehicle so that the oil will
pick up any sediment and drain easily. Then stop the
vehicle.
• Place an oil pan beneath the transmission case.
• Remove the transmission oil drain plug [A], and let the oil
drain completely.
• Check the gasket at the drain plug for damage.
Replace the gasket with a new one if it is damaged.
plug with the gasket.
Torque - Transmission Oil Drain Plug: 15 N·m (1.5 kgf·m,
11 ft·lb)
• Fill the transmission case with a good quality oil as spec-
ified in the table.
• Check the oil level.
Transmission Oil
Type: API "GL-5" 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)
Oil Level: Between upper and lower level lines
Final Drive
Front Final Gear Case Oil Change
• Warm up the oil by running the vehicle so that the oil will
pick up any sediment and drain easily. Then stop the
vehicle.
• Park the vehicle so that it is level, both side-to-side and
front-to-rear.
• Remove:
Front Guard (see Frame chapter)
Front Final Gear Case Skid Plate (see Front Final Gear
Case Oil Level Inspection in the Final Drive chapter)
• Place an oil pan beneath the front final gear case and
remove the drain plug [A].
WARNING
When draining or filling the final gear case, be care-
ful that no oil gets on the tire or rim. Clean off any
oil that inadvertently gets on them with a high-flash
point solvent.
plug with a new aluminum gasket, and tighten it.
Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)
• Fill the gear case up to the bottom [B] of filler opening [A]
with the oil specified below.
Front Final Gear Case Oil
Type: API "GL-5 or GL-6" hypoid gear oil
for LSD (Limited Slip Differential gears)
Viscosity: SAE 90, or SAE 140
Capacity: 0.4 L (0.4 US qt)
Oil Level Filler opening level
NOTE
○"GL-5 or GL-6" indicate a quality and additive rating.
• BeFiller
sure the O-ring [B] is in place, and tighten the filler cap.
Opening [A]
Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb)
Wheels/Tires
Wheels Nuts Tightness Inspection
• Check the tightness of all the wheel nuts.
If there are loose nut, first loosen by 1/2 turn, then re-
torque them to the specified torque.
Torque - Wheel Nuts: 140 N·m (14 kgf·m, 100 ft·lb)
○Tighten the wheel nuts [1] ~ [4] in a criss-cross pattern.
Tire Wear Inspection
• Examine the tire for damage and wear.
If the tire is cut or cracked, replace it.
○Lumps or high spots on the tread or sidewalls indicate
internal damage, requiring tire replacement.
○Remove any foreign objects from the tread. After re-
moval, check for leaks with a soap and water solution.
• 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.
If any of the measurements is less than the service limit,
replace the tire.
Tire Tread Depth
Service Limit 3 mm (0.12 in.)
Standard Tire
23 × 11.00-10 DUNLOP KT869
Front and rear:
Tubeless
Brakes
Brake Fluid Level Inspection
• With the vehicle on level ground, check that the fluid level
in the reservoir is between the upper (MAX) and lower
(MIN) level lines.
○Look 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.
WARNING
Change the fluid in the brake system completely if
the fluid level is low but the type and brand of the
fluid already in the reservoir are unknown.
• Tilt up the front cargo hood.

• Rubber Cap [A]
Remove:
Front Cargo Compartment [B]

Front [C]
• FillUpper
the reservoir to the upper level line [A].
Level Line (MAX)
Lower Level Line (MIN) [B]
Hole [C] of Front Cargo Compartment
• Apply the brake forcefully for a few seconds and check for
fluid leakage around the fittings.
WARNING
If the brake pedal has a soft or "spongy feeling"
when it is applied, there might be air in the brake
lines or the brake may be defective. Since it is dan-
gerous to operate the vehicle under such condi-
tions, have the brake system serviced immediately.
Brake Fluid Change

• Tilt up the front cargo hood [A] and remove the front cargo
compartment [B] (see Frame chapter).
Front [C]
• Level the brake fluid reservoir.
NOTE
○The 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.
• Remove
chapter).
the wheel for extra clearance (see Wheels/Tires
• Remove the reservoir cap.

• cylinder. rubber cap from the bleed valve on the wheel
Remove the
• 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]
Front [C]
NOTE
○Start with the rear left or right wheel and finish with the
front left or right wheel.
• Fill the reservoir with new brake fluid.

• Change the install
Temporarily the reservoir cap.
•1. Open bleed valve. as follows:
brake fluid
2. Pump brake pedal and hold it.

3. Close bleed valve.
4. Release brake pedal.
• Tighten:
Torque - Bleed Valves: 5.9 N·m (0.6 kgf·m, 52 in·lb)
• Repeat the previous step for each wheel.
• When brake fluid changing is finished, add the fluid to the
upper level in the reservoir.
• 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
Brakes chapter).
WARNING
If the brake pedal has a soft or "spongy feeling"
when it is applied, there might be air in the brake
line or the brake may be defective. Since it is dan-
gerous to operate the vehicle under such condi-
tions, bleed the air from the brake line immediately.

Torque - Master Cylinder Reservoir Cap: 3.4 N·m (0.35
kgf·m, 30 in·lb)
Brake Pedal Play Inspection

• Check brake pedal free play [A].
Brake Pedal Free Play
Standard: 2 ~ 10 mm (0.08 ~ 0.39 in.)
If free play is not correct, adjust it.
• Remove
ter).
the front cargo compartment (see Frame chap-
• Loosen the locknut [A] and turn [B] the push rod to obtain
the correct amount of free play.
• Tighten:
Torque - Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Check
drag.
the brake for good braking power and no brake
WARNING
Incorrect adjustment with insufficient free play can
cause brake heating and drag. Skidding and loss of
control may result.
Brake Master Cylinder Cup and Dust Cover
Replacement
• Remove the master cylinder (see Master Cylinder Re-
moval in the Brakes chapter).
• Remove the piston stop bolt [G].
• the circlip pliers.
Remove the dust cover [A] and then the retainer [B] with
Special Tool - Inside Circlip Pliers: 57001-143

○Remove the piston assembly (two pistons) by lightly tap
the master cylinder on a wooden block.
Pistons [C]
Springs [D]
Secondary Cup [E]
Primary Cup [F]
Master Cylinder [H]
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
•○Assemble the master cylinder:

Clean 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.
CAUTION
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.
○Push the piston assembly in all the way with a screwdriver
and install the piston stop bolt. Use a new aluminum
washer.
○Tighten:
Torque - Piston Stop Bolt: 8.8 N·m (0.9 kgf·m, 78 in·lb)
Reservoir Clamp Bolt: 5.9 N·m (0.6 kgf·m, 52 in·lb)
• Install the master cylinder (see Master Cylinder Installa-
tion in the Brakes chapter).
Brake Hose and Pipe Inspection
• The 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.
• The metal pipe will rust if 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 in this section).
Brake Hose and Pipe Replacement
• To remove the brake pipes [A], unscrew the nipples [B].
• and/or
To remove the hoses [C], remove the banjo bolts [D]
pull out the retainers [E] (see below).
Front [F]
○The front cargo compartment inside is shown.
• Immediately wipe up any brake fluid that spills.
CAUTION
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
• Use a new copper washer for each side of the hose fittings
at the master cylinder.
• Apply brake fluid to the threads of the nipple [B] of the
brake pipe [A].
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Nipple: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Check that the brake line has proper fluid pressure and
no fluid leakage.
○The left front brake drum is shown.
○The left front knuckle is shown.
Brake Pipe [A]
Nipple [B]
Brake Hose [C]
Retainer [E]
Left View with the center floor panel removed

Brake Hose and Pipe [A]
Nipple [B]
○The middle-left of the vehicle is shown with the cargo bed
tilted up.
Brake Pipe [A]
Nipple [B]
Brake Hose [C]
Retainer [E]
Front [F]
Torque Converter Outer Cover [G]
○The rear-left brake line is shown.

Brake Pipe [A]
Nipple [B]
Brake Hose [C]
Retainer [E]
Front [F]
Brake Wear Inspection

• Remove the brake drum (see Brake Drum Removal in the
Brakes chapter).
• Measure the inside diameter of the drum at several points.
If any measurement is greater than the service limit, re-
place the drum.
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
180.000 ~ 180.160 mm (7.0866 ~ 7.0929
Standard:
in.)
• Remove the brake drum for brake shoe inspection (see

Brake Drum Removal in the Brakes chapter).
• Measure the lining thickness at several points.
Brake Shoe Lining thickness
If any measurement is less than the service limit, replace
both shoes as a set.
If the lining thickness is greater than the service limit, do
the following before installing the shoes.
• File or sand down any high spots on the surface on the
lining.
• Use a wire brush to remove any foreign particles from the
lining.
• Wash off any oil or grease with an oilless solvent.
CAUTION
Do not use a solvent which will leave an oily
residue. The shoes will have to be replaced.
Brake Wheel Cylinder Assembly Replacement
(Front Brake Panel)
• Remove:
Brake Drum (see Brake Drum Removal in the Brakes
chapter.)
○The left front brake panel is shown.
• Remove the brake shoe springs [A] and brake shoes [B]
individually.
○Push the shoe hold-down springs [C] and twist the pins
[D] to remove the shoes.
NOTE
○Wrap the brake shoes with a clean cloth to protect the
linings from grease or dirt.
•○Remove the brake pipe nipple [A] and plug the nipple.
Immediately wipe up any brake fluid that spills.
CAUTION
diately.
• Unscrew the mounting bolts [B] and take off [C] the front
brake wheel cylinder.
(Rear Brake Panel)

• Remove the brake shoes [A] in the same way as in the
front brake panel.
Rear Brake Wheel Cylinder [B]
(Rear Brake Panel)

• Remove the brake pipe nipple [A] and plug the nipple.
• Unscrew the mounting nuts [B] and take off [C] the rear
brake wheel cylinder.
Front [D]
• Replace the rear wheel cylinder with a new one.

• can be reinstalled
Set the brake shoe clearance adjuster so that the drum
on the panel assembly.
(Front Brake Panel)
○Turn [A] either end of the cylinder fully while holding the
other end [B]. Both ends are put into the cylinder.
(Rear Brake Panel)

○Push the ratchet [A] forwards and in to reset the shoe
clearance adjuster from the protruding position to its orig-
inal position. The stop [B] sets the position.
Parking Brake Lever Linkage (left) [A] of Rear Brake

Ratchet [B]
Protruding Position [C]
Shoe Clearance Adjuster [E]
Front [F]

Ratchet [B]
Original Position [D]
Front [F]
• Apply brake fluid to the threads of the brake pipe nipple
and tighten it.
Torque - Brake Pipe Nipple: 18 N·m (1.8 kgf·m, 13 ft·lb)
Wheel Cylinder Mounting Bolts (front): 11 N·m (1.1
kgf·m, 95 in·lb)
Wheel Cylinder Mounting Nuts (rear): 7.8 N·m (0.8
kgf·m, 69 in·lb)
• Grease the following (front and rear brakes):

Brake Panel and Brake Shoe Contact Points [A]
Wheel Cylinder Piston Ends [A]
Brake Shoe Anchor Ends [A]
○The left front brake is shown.
(Rear Brake Panel)

• Grease the shoe clearance adjuster pivots [A].
(Rear Brake Panel)

• Pack the gaps [A] with a little grease.
• Bleed the brake line after drum installation (see Brake
Line Air Bleeding in the Brakes chapter).
• Be sure to check the brake system for good braking
power, no brake drag and no fluid leakage.
WARNING
Do not attempt to drive the vehicle until a full brake
pedal is obtained. Pump the brake pedal until the
wheel cylinders operate and the brake shoes are
against the drums. The brake will not function on
the first application of the pedal if this is not done.
• Adjust:
Parking Brake Lever (see Parking Brake Lever Inspec-
tion in this section)
Parking Brake Lever Inspection
•○Check parking brake lever travel [A] by feeling clicks.
Pull the parking brake lever [B] upward slowly all the way.
Count the number of notches (clicks) during lever travel.
Front [C]
○The vehicle should not roll while parked.
Parking Brake Lever Travel
Standard: 8 ~ 12 notches (clicks)
at 200 N (20 kgf, 44 lb)
• Release
position.
the parking brake and return the lever to its rest
If the lever travel is not correct, adjust it.
• Pull up the rubber boot [A].
• Loosen the locknut [B] and turn the adjusting nut [C] to
obtain the correct amount of lever travel.
• Tighten the locknut.
Front [D]
• Check the parking brake for good braking power and
when released, no brake drag.
WARNING
Incorrect adjustment with insufficient free play can
cause brakes to overheat and drag. Skidding and
loss of control may result.
NOTE
○If the parking brake lever travel cannot be adjusted with
the adjusting nut at the lever, use the adjusters [A] be-
hind the parking brake lever and adjusters [B] near the
rear wheels. Be sure to adjust both the left and right
cables evenly, and then securely tighten the adjuster
mounting nuts [C].
Behind the parking lever [D]
○The left rear brake is shown [E].

Parking Lever Adjuster [B]
Adjuster Mounting Nuts [C]
Steering
Steering Inspection
•○Check steering wheel free play [A].
Set 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 chapter)
Intermediate Shaft Clamp Bolts (see Steering chapter)
Steering Gear Assembly Mounting Bracket Bolts (see
Steering chapter)
Steering Gear Assembly Mounting Rubber Dampers
Tie-rod End Nuts (see Wheels/Tires chapter)
Steering Gear Preload Adjustment (see Steering chap-
ter)
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
• Visually inspect the dust boots [A] at both the ends of the
steering gear assembly.
Front [B]
If there is any signs of deterioration, cracks, or damage,
replace the steering gear assembly together with these
boots.
Frame
Seat Belt Inspection
•○Check that each seat belt functions properly.
Push the latch plate [A] into the buckle [B] until it clicks the
latch plate must slide smoothly into the buckle, the click
sound shows it is securely latched.
○Push the red button [C] in the buckle to make sure it re-
lease freely.
•Check the belt webbing for wear, cuts or damage.
If any irregularities are found, replace the seat belt.
Electrical System
Electrolyte Level 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.
•○Remove the filler caps [A] on the battery.

Lift the side of the cap [B] opposite the terminals, and then
lift the side of the cap nearest the terminals.
• The electrolyte level should be between the upper and

lower levels.
○Upper level is bottom [A] of the split ring [B].
○Lower level is top of the plates [C].
If the level of electrolyte in any cell is below the lower level,
add only distilled water to the upper level of the cell.
CAUTION
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
• Check battery condition by testing the specific gravity of

the electrolyte in each cell with a hydrometer.
○Read the level of the electrolyte [A] on the floating scale.
Specific Gravity
Standard: 1.265 @20°C (68°F)
If the specific gravity is below 1.20 (charge 70%), the bat-

tery needs to be charged.
NOTE
○The specific gravity of the electrolyte varies with
changes in temperature, so the specific gravity reading
must be corrected for the temperature of the electrolyte.
○Celsius: Add 0.007 points to reading for each 10°C
(50°F) above 20°C (68°F) or subtract 0.007 points for
each 10°C (50°F) below 20°C (68°F)
○Fahrenheit: 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)
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.
If the specific gravity of all the cells is 1.265 or more, the
battery is fully charged.
Charging Condition Inspection (Conventional Type
Battery)
○Battery charging condition can be checked by measuring
battery terminal voltage.
• Disconnect the battery terminal leads.
CAUTION
Be sure to disconnect the negative terminal leads
first.
• Measure the battery terminal voltage.

NOTE
○Measure with a digital voltmeter [A] which can be read
to 0.1 volt.
If the reading is below the specified, refreshing charge is
required.
Battery Terminal Voltage
Standard: 12.6 V or more
Brake Light Switch Inspection

• Check the operation of the brake light switch by depress-
ing the brake pedal. The brake light should go on after 10
mm (0.4 in.) of pedal travel [A].
If it does not, adjust the brake light switch [A] up or down.

To change the switch position, turn the adjusting nut [B].
Brake Light Switch Timing
Standard: ON after 10 mm (0.4 in.) of pedal travel
CAUTION
To avoid damaging the electrical connections in-
side the switch, be sure that the switch body does
not turn during adjustment.
General Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever 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.

Seat Brackets
Cargo Bed Mounting Pins
Throttle Pedal Pivot
Throttle Cable Upper End
Brake Pedal Pivot
Transmission Shift Lever Pivot
Differential Shift Lever Pivot
2WD/4WD Shift Lever Pivot
Differential Shift and 2WD/4WD Shift Cable Lower End
Propeller Shaft Bearing [A] (under seat)
○Grease the propeller shaft bearing using the grease nip-
ple [B].
Cables: Lubricate with Cable Lubricant.
Throttle Inner Cable
Differential Shift Inner Cable
2WD/4WD Shift Inner Cable
•Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a pressure cable
lubricator with an aerosol cable lubricant.
Cables: Lubricate with Engine Oil.
Parking Brake Cables
• With the cable disconnect at both ends, the cable should

move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Bolts, Nuts, and Fasteners
Tightness Inspection
• 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
○Check the engine fastener tightness when the engine is
cold (at room temperature).
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
(see Torque and Locking Agent in this chapter).
If cotter pins are damaged, replace them with new ones.
Nut, Bolt, and Fasteners to be checked

Engine
Engine Mounting Bolts
Exhaust Pipe Holder Nuts
Exhaust Pipe and Muffler Clamp Bolt
Muffler Mounting Bolts
Throttle Pedal Pivot Clip
Fuel Tank Holder Nuts
Transmission/Final Drive
Axle Nuts and Cotter Pins
Drive Shaft Bracket Mounting Nuts
Transmission Shift Cable Upper End Clip
Transmission Shift Lever Clamp Bolt
Differential Shift Lever Pivot Clip
Differential Shift Cable Upper End Clip
Differential Shift Lever Mounting Nut
Propeller Shaft Bearing Mounting Nuts
2WD/4WD Shift Lever Pivot Clip
2WD/4WD Shift Lever Mounting Nut
Hi/Low Shift Lever Pivot Clip
Hi/Low Shift Cable Upper End Clip
Hi/Low Shift Lever Mounting Nut
Wheels
Wheel Nuts
Brakes
Master Cylinder Mounting Bolts
Master Cylinder Push Rod Clevis Pin Clip
Parking Brake Lever Assembly Mounting Bolts
Parking Brake Cable Lower End Clevis Pin Cotter Pins
Brake Pedal Pivot Shaft Cotter Pin
Suspension
Suspension Arm Pivot Bolts
Strut Mounting Nuts
Strut Clamp Nuts and Cotter Pins
Leaf Spring Mounting Nuts
Shock Absorber Mounting Nuts
Steering
Steering Wheel Mounting Nut
Intermediate Shaft Clamp Bolts
Tie-rod End Nuts and Cotter Pins
Tie-rod End Locknuts
Suspension Arm Joint Nuts and Cotter Pins
Main Shaft Mounting Bolts and Nuts
Frame
Front and Rear Bar Mounting Bolts and Nuts
Front Guard Mounting Nuts
Cargo Bed Hook Mounting Bolts
Cargo Bed Mounting Pin Clips
Screen Mounting Nuts
Seat Bracket Nuts
Seat Back Mounting Nuts
Seat Belt Mounting Bolts
Battery Holder Nuts
Skid Plate Mounting Bolts
Rear End Sub-frame Mounting Nuts
FUEL SYSTEM 3-1
Fuel System
Table of Contents
3
Exploded View........................................................................................................................ 3-2
Specifications ......................................................................................................................... 3-6
Special Tool ............................................................................................................................ 3-7
Throttle Pedal and Cable........................................................................................................ 3-8
Throttle Pedal Free Play Inspection.................................................................................. 3-8
Throttle Pedal Free Play Adjustment ................................................................................ 3-8
Full Throttle Pedal Position Adjustment ............................................................................ 3-8
Throttle Cable Installation ................................................................................................. 3-8
Throttle Cable Lubrication and Inspection ........................................................................ 3-9
Fuel Injection Nozzle .............................................................................................................. 3-10
Fuel Injection Nozzle Removal ......................................................................................... 3-10
Fuel Injection Nozzle Installation ...................................................................................... 3-10
Fuel Injection Nozzle Inspection ....................................................................................... 3-10
Fuel Injection Pump................................................................................................................ 3-12
Idle Speed Inspection ....................................................................................................... 3-12
Idle Speed Adjustment...................................................................................................... 3-12
Maximum Engine Speed Inspection ................................................................................. 3-12
Maximum Engine Speed Adjustment................................................................................ 3-12
Fuel Injection Pipe Removal ............................................................................................. 3-13
Fuel Injection Pipe Installation ......................................................................................... 3-13
Fuel Injection Pump Removal ........................................................................................... 3-14
Fuel Injection Pump Installation ........................................................................................ 3-14
Fuel Injection Pump Timing Inspection ............................................................................. 3-15
Fuel Injection Pump Inspection and Repair ...................................................................... 3-17
Fuel Injection Pump Troubleshooting ..................................................................................... 3-18
Air Cleaner.............................................................................................................................. 3-25
Air Cleaner Element Cleaning........................................................................................... 3-25
Air Cleaner Housing Removal........................................................................................... 3-26
Air Cleaner Housing Dust and/or Water Inspection .......................................................... 3-26
Fuel Filter................................................................................................................................ 3-27
Fuel Filter Removal........................................................................................................... 3-27
Fuel Filter Installation........................................................................................................ 3-27
Fuel Filter Cartridge Replacement .................................................................................... 3-27
Water Draining .................................................................................................................. 3-27
Fuel Tank ................................................................................................................................ 3-28
Fuel Tank Removal ........................................................................................................... 3-28
Fuel Tank Installation ........................................................................................................ 3-28
Fuel Tank Cleaning/Inspection.......................................................................................... 3-28
3-2 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-3
Exploded View
G: Apply grease.
R: Replacement Parts.
3-4 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Fuel Injection Nozzles 59 6.0 43
2 Linkage Pipe Nuts 27 2.8 20
3 Idle Adjusting Screw Locknut 5.6 0.57 50 in·lb
4 Maximum Speed Set Screw Locknut 6.9 0.70 61 in·lb
5 Fuel Injection Pipe Mounting Nuts 25 2.5 18
6 Fuel Injection Pipe Clamp Bolts 7.4 0.75 65 in·lb
7 Distributor Head Bolt 17 1.7 12
8 Fuel Injection Pump Mounting Nuts 20 2.0 14
9 Fuel Injection Pump Bracket Bolts 20 2.0 14
10 Fuel Filter Mounting Bolts 20 2.0 14
11 Air Vent Plug 4.9 0.50 43 in·lb
12 Fuel Injection Pump Gear Nut 64 6.5 47
13. Fuel Return Hose (from Fuel Injection Pump to Fuel Tank).
14. Fuel Supply Hose (from Fuel Filter to Fuel Injection Pump).
15. Fuel Supply Hose (from Fuel Tank to Fuel Filter).
AD: Apply adhesive agent.
R: Replacement Parts.
3-6 FUEL SYSTEM
Specifications

Throttle Pedal and Cable
Throttle Pedal Free Play 5 ~ 10 mm (0.2 ~ 0.4 in.) – – –
Fuel Injection Nozzle
Fuel Injection Nozzle Injection 13 239 ∼ 14 220 kPa
– – –
Pressure (135 ~ 145 kgf/cm², 1 920 ∼ 2 062 psi)
Fuel Injection Pump
Idle Speed 850 ~ 950 r/min (rpm) – – –
Maximum Engine Speed (no
3 800 ~ 3 900 r/min (rpm) – – –
load)
Injection Timing (plunger stroke) 0.81 ±0.03 mm
– – –
(0.0319 ±0.0012 in.)
FUEL SYSTEM 3-7
Special Tool
Dial Gauge Adapter:
57001-1430
3-8 FUEL SYSTEM
Throttle Pedal Free Play Inspection
• Refer to the Fuel System in the Periodic Maintenance
chapter.
Throttle Pedal Free Play Adjustment
chapter.
Full Throttle Pedal Position Adjustment
• Loosen the locknut [A].
• Screw in the throttle pedal stop bolt [B].
• Remove:
Cargo Bed (tilt up)
Injection Pump Cover Bolts [A]
Injection Pump Cover [B] (only)
○Retighten the bolts with the bracket.
• Depress the throttle pedal until the speed control lever [A]
on the injection pump is in the fully opened position, and
hold it there.
• Turn the throttle pedal stop bolt until the bolt head lightly
touches the bottom of the throttle pedal.
• Tighten the locknut securely.
Throttle Cable Installation

• Route the throttle cable correctly (see Appendix chapter).
• Throttle Pedal Free Play Inspection (see Periodic Main-
Adjust:
tenance chapter)
WARNING
Operation with incorrectly routed or improperly
adjusted cable could result in an unsafe operating
condition.
FUEL SYSTEM 3-9
Throttle Cable Lubrication and Inspection
• Whenever the throttle cable is removed or in accordance
with the Periodic Maintenance Chart in the Periodic Main-
tenance chapter, lubricate the cable.
• Refer to the General Lubrication in the Periodic Mainte-
nance chapter.
3-10 FUEL SYSTEM
Fuel Injection Nozzle Removal
• Fuel Injection Pipes (see Fuel Injection Pipe Removal)
Remove:
Fuel Return Hose [A]

Linkage Pipe Nuts [B]
Linkage Pipe [C]
• Remove:
Washer [A]
Fuel Injection Nozzle [B] and Gasket
CAUTION
Handle the fuel injection nozzles with extreme care.
Do not drop the nozzles.
Fuel Injection Nozzle Installation

• Install:
New Gasket [A]
Fuel Injection Nozzle [B]
Torque - Fuel Injection Nozzles: 59 N·m (6.0 kgf·m, 43 ft·lb)
• Install:
New Washers [C]
Linkage Pipe [D]
Linkage Pipe Nuts [E]
Torque - Linkage Pipe Nuts: 27 N·m (2.8 kgf·m, 20 ft·lb)
• Install:
Fuel Return Hose
Fuel Injection Pipes (see Fuel Injection Pipe Installation)
Fuel Injection Nozzle Inspection
WARNING
The injected fuel is highly flammable. Don’t draw
a flame near the injected fuel. Fuel is highly pres-
surized and has enough kinetic energy just after
sprayed to penetrate into the human body causing
injury. Don’t place your fingers, hands, or other
parts of your body close to the nozzle during injec-
tion nozzle tests in the air. Stay 30 cm (12 inches)
or more a way from the nozzle.
NOTE
○Refer to Fuel Injection Pump Inspection and Repair for
nozzle repair information.
FUEL SYSTEM 3-11
Injection Pressure Check
• Install the fuel injection nozzle on a nozzle tester.
• Quickly move the tester lever up and down so that the
injection nozzle sprays two to three times.
○This step blows off any carbon deposits on the injection
nozzle port.
• Move the lever very slowly, gradually raising the pressure.
• Measure the maximum pressure just as the pointer of the
pressure gauge drops suddenly.
Fuel Injection Nozzle Injection Pressure
Standard: 135 ∼ 145 kgf/cm² (1 920 ∼ 2 062 psi)
If the measured pressure does not comply with the spec-
ification, replace the injection nozzle.
Leakage Check
•Slowly depress the tester lever, until the pressure reaches
about 120 kgf/cm² (1 707 psi).
•Holding this pressure for about 10 seconds, and make
sure that no fuel leaks from the nozzle’s injection port or
around the retaining nut.
Checking for "Buzzing" and Spray Pattern

•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.
•Make sure that "buzzing" occurs during these strokes.
NOTE
○When this "buzzing" occurs, you can feel a pulsation
transmitted to your hand through the nozzle tester han-
dle while the nozzle injection is taking place.
○When 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".
○These 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.
○Generally, a nozzle that "buzzes" is good, because a
spray condition where intermittent pulsations are gen-
erated assures good "cut-off" of the fuel supply.
• 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 center line of the nozzle.
• Ensure that the nozzle does not drip.
3-12 FUEL SYSTEM
Fuel Injection Pump
Idle Speed Inspection
chapter.
Idle Speed Adjustment
chapter.
Maximum Engine Speed Inspection
• Check the full throttle pedal position (see Full Throttle
Pedal Position Adjustment).
• Set the parking brake.
• Be sure the transmission is in Neutral.
• Tilt upthetheengine
Start and warm it up thoroughly.
• Check the maximum
cargo bed.
• tachometer. engine speed with a suitable
If the maximum engine speed is not in the specified range,

adjust it.
Maximum Engine Speed (no load)
Standard: 3 800 ∼ 3 900 r/min (rpm)
Maximum Engine Speed Adjustment

• Set the parking brake.
• Tilt up thethecargo
Be sure transmission is in Neutral.
• Remove the injectionbed.
• Remove the injection pumppump cover bolts [A].
• Retighten the bolts with the cover [B] and collers [C].
• bracket [D].
• Cut and remove the wire [A] on the maximum speed set
screw [B].
• Turn thethemaximum
Loosen locknut [C].
• engine speed is correct.
speed set screw until the maximum
• Tighten:
Torque - Maximum Speed Set Screw Locknut: 6.9 N·m (0.70
kgf·m, 61 in·lb)
• Lock the maximum speed set screw with a wire or paint
on the locknut and pump housing.
FUEL SYSTEM 3-13
Fuel Injection Pump
Fuel Injection Pipe Removal
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.
CAUTION
Take care to prevent any dirt from entering injection
nozzle holes or delivery valve ports when fuel deliv-
ery lines are removed.
• Remove:
Air Duct [A]
Fuel Injection Pipe Clamp Bolts [B]
Fuel Injection Pipe Clamps [C]
• Loosen:
Fuel Injection Pipes Upper Nuts [D]
• 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

•○Install the fuel injection pipes using the following steps.
Temporarily, tighten the upper and lower nuts then tighten
them.
○First, install the No. 2 injection pipe [A].
○Secondly, install the No. 1 injection pipe.
○Finally, install the No. 3 injection pipe.
• Tighten:
Torque - Fuel Injection Pipe Mounting Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Fuel Injection Pipe Clamp Bolts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
3-14 FUEL SYSTEM
Fuel Injection Pump
Fuel Injection Pump Removal
• Remove:
Engine (see Engine Removal/Installation chapter)
Fuel Injection Pump Gear (see Timing Gear Case Re-
moval 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]
• Remove:
Fuel Injection Pump Mounting Nuts [A]
Fuel Injection Pump [B]
Fuel Injection Pump Installation

• Install:
New O-ring [A]
• Install:
Fuel Injection Pump (temporary)
○Align the timing marks [A] on the injection pump and tim-
ing gear case.
○Tighten the mounting nuts with fingers.
FUEL SYSTEM 3-15
Fuel Injection Pump
• Install:
Fuel Injection Pump Gear, Timing Gear Case Cover and
Crankshaft Pulley (see Timing Gear Case Installation in
Crankshaft/Cylinder Block chapter)
• Adjust the fuel injection pump timing (see Fuel Injection
Pump Timing Inspection).
• Tighten:
Torque - Fuel Injection Pipe Mounting Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Fuel Injection Pipe Clamp Bolts: 7.4 N·m ( 0.75
kgf·m, 65 in·lb)
• Adjust:
Maximum Engine Speed (New Injection Pump, see Max-
imum Engine Speed Inspection)
Idle Speed (see Fuel System in the Periodic Mainte-
nance chapter)
Fuel Injection Pump Timing Inspection
• Remove:
Fan Belt Cover (see Cooling System section in the Pe-
riodic Maintenance chapter)
Hose [A]
Cylinder Head Cover Bolts [B] and Washers [C]
• Turn the crankshaft pulley [A] clockwise, and position the

crankshaft at #1 piston TDC on the compression stroke.
○Align the timing mark [B] on the crankshaft pulley and
reference point [C] on the timing case cover.
○If the intake and exhaust valves for #1 cylinder have no
clearance, turn the crankshaft pulley one revolution.
• Remove:
Fuel Injection Pipes [A] (see Fuel Injection Pipe Re-
moval)
Distributor Head Bolt [B]
3-16 FUEL SYSTEM
Fuel Injection Pump
• Install:
Dial Gauge Adapter [A] and Dial Gauge [B]
Special Tool - Dial Gauge Adapter: 57001-1430
• Slowly turn the crankshaft pulley counterclockwise about

30° until the dial gauge needle stops. Pump plunger lift is
zero at this point.
• Set the dial gauge to the “0” position.
• Slowly turn the crankshaft pulley clockwise, stopping at

#1 piston TDC on the compression stroke.
NOTE
○Do 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.
• Note dial gauge reading.

Injection Timing 0.81 ±0.03 mm
(Plunger Stroke): (0.0319 ±0.0012 in.)
If the gauge reading is within the specification, the injec-

tion pump is properly timed.
If the reading 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
○Do 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.
• Remove:
Torque Converter Case (see Torque Converter System
chapter)
• Loosen:
Fuel Injection Pump Mounting Nuts [A]
FUEL SYSTEM 3-17
Fuel Injection Pump
• Loosen:
Fuel Injection Pump Bracket Bolt [A]
• 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. (0.032 ±0.001 in.)
• Hold the fuel injection pump in this position and tighten
the fuel injection pump mounting nuts.
NOTE
○Do 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.
• Tighten:
Torque - Fuel Injection Pump Mounting Nuts: 20 N·m (2.0
kgf·m, 14 ft·lb)
Fuel Injection Pump Bracket Bolts: 20 N·m (2.0
kgf·m, 14 ft·lb)
• To verify that the timing is correct, turn the crankshaft pul-

ley counterclockwise until the dial indicator reads “0”.
• Then turn the crankshaft pulley clockwise until the timing
mark on the crankshaft pulley aligns with reference point
on the timing case cover.
• The indicator should be within the specification.
Injection Timing 0.81 ±0.03 mm
(Plunger Stroke): (0.0319 ±0.0012 in.)
If the indicator reading is not within the specification, re-
peat the procedure.
• Remove:
Dial Gauge Adapter and Dial Gauge
• Install:
Distributor Head Bolt and Washer
• Tighten:
Torque - Distributor Head Bolt: 17 N·m (1.7 kgf·m, 12 ft·lb)
Fuel Injection Pump Inspection and Repair

NOTE
○Do 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.
• Refer to the troubleshooting section to check of the pump.

If the pump and nozzle are malfunction, replace them, or
consult a reliable repair shop (ex. Denso Service Station).
3-18 FUEL SYSTEM
Fuel Injection Pump Troubleshooting
FUEL SYSTEM 3-19
3-20 FUEL SYSTEM
FUEL SYSTEM 3-21
3-22 FUEL SYSTEM
FUEL SYSTEM 3-23
3-24 FUEL SYSTEM
FUEL SYSTEM 3-25
Air Cleaner
A clogged engine air cleaner restricts the engine’s air in-
take, increasing fuel consumption, reduction engine power.
CAUTION
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
• Remove:the clamps [A].
Unlock
• Air Cleaner Cover [B]
• Remove:
Element [A]
• of a screwdriver.
Clean the element by tapping gently with the handle end
If the element is very dirty or damaged, replace the ele-

ment.
• Carefully clean out the air cleaner cover.
•○Install the cover and lock the clamps.

Face the TOP mark [A] upward.
3-26 FUEL SYSTEM
Air Cleaner
•○Reset the Air Filter Restriction Gauge [A].

After 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

• Air Ducts [A]
Remove:
Mounting Bolts [B]

Air Cleaner Housing [C]
Air Cleaner Housing Dust and/or Water Inspection

• Push open the drain tube [A] on the bottom of the air
cleaner housing.
FUEL SYSTEM 3-27
Fuel Filter
Fuel Filter Removal
• Fuel Hoses [A]
Remove:
Fuel Filter Mounting Bolts [B]

Fuel Filter [C]
Fuel Filter Installation

• Install:
Fuel Filter
Fuel Hoses
• Tighten:
Torque - Fuel Filter Mounting Bolts: 20 N·m (2.0 kgf·m, 14
ft·lb)
•○Bleed the air from the fuel filter.
Loosen the air vent plug [A].
○Pump the priming button [B] until the fuel comes out of
the air vent.
○Tighten the air vent plug securely.
Torque - Air Vent Plug: 4.9 N·m (0.50 kgf·m, 43 in·lb)
○Wipe up any spilled fuel.
Fuel Filter Cartridge Replacement
• Refer to Fuel Filter Element Replacement in the Periodic
Maintenance chapter.
Water Draining
• Refer to Fuel Filter Draining in the Periodic Maintenance
chapter.
3-28 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
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.
• Remove:
Cargo Bed (tilt up)
Fuel Hose [A] (disconnect) Fuel Tank Holders [C]
Fuel Tank Holder Nuts [B] Fuel Tank [D]
○Slide back the fuel tank and remove it from the vehicle.
Fuel Tank Installation
• Ifinstall
the rubber dampers [A] and/or trim [B] were removed,
them onto the frame or fuel tank with an adhesive.
Fuel Tank Cleaning/Inspection

WARNING
Clean the tank in a well-ventilated area, and take
care that there is no spark or flame anywhere near
the working area. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
point solvents to clean the tank.
• Remove the fuel tank and drain it.

• Pour somethehigh
Remove fuel level gauge [A].
• shake the tank toflash-point solvent into the fuel tank and
remove dirt and fuel deposits.
• Pour the solvent out of the tank.
• Visually tank
Dry the with compressed air.
• fuel tank cap forthe
inspect gaskets on the fuel level gauge and
any damage.
Replace the gaskets if they are damaged.
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................ 4-2
Specifications ......................................................................................................................... 4-4 4
Flow Chart .............................................................................................................................. 4-5
Coolant ................................................................................................................................... 4-6
Coolant Level Inspection................................................................................................... 4-6
Coolant Draining ............................................................................................................... 4-6
Coolant Filling ................................................................................................................... 4-6
Water Pump............................................................................................................................ 4-7
Water Pump Removal ....................................................................................................... 4-7
Water Pump Installation .................................................................................................... 4-7
Water Pump Inspection..................................................................................................... 4-8
Radiator and Radiator Fan ..................................................................................................... 4-9
Radiator Removal ............................................................................................................. 4-9
Radiator Inspection ........................................................................................................... 4-11
Radiator Cleaning ............................................................................................................. 4-11
Radiator Cap Inspection ................................................................................................... 4-11
Thermostat ............................................................................................................................. 4-12
Thermostat Removal......................................................................................................... 4-12
Thermostat Installation...................................................................................................... 4-12
Thermostat Inspection ..................................................................................................... 4-12
Hoses and Pipes .................................................................................................................... 4-13
Hose and Pipe Installation ................................................................................................ 4-13
Hose Inspection ................................................................................................................ 4-13
Radiator Fan Switch, Water Temperature Warning Light Switch............................................ 4-14
Radiator Fan Switch Removal .......................................................................................... 4-14
Water Temperature Warning Light Switch Removal ......................................................... 4-14
Radiator Fan Switch, Water Temperature Warning Light Switch Installation .................... 4-15
Radiator Fan Switch, Water Temperature Warning Light Switch Inspection..................... 4-15
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Water Pump Mounting Bolts And Nuts 20 2.0 14
2 Fan Mounting Bolts 8.8 0.90 78 in·lb
3 Thermostat Housing Cap Bolts 7.8 0.80 69 in·lb
4 Radiator Fan Switch 25 2.5 18
5 Water Temperature Warning Light Switch 27 2.8 20 L
6 Thermostat Housing Cap Plug – – – L
7 Radiator Mounting Bolts 8.8 0.90 78 in·lb
8 Radiator Screen Bolts 8.8 0.90 78 in·lb
9 Coolant Reservoir Tank Bolts 4.5 0.45 40 in·lb
10 Coolant Drain Plug 25 2.5 18 L
11 Coolant Inlet Bolts 7.8 0.80 69 in·lb
12. Radiator Fan Breaker (KAF950B7F)
G: Apply grease to O-rings
L: Apply a non-permanent locking agent.
4-4 COOLING SYSTEM
Specifications

Coolant
Type 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°C (–31°F) – – –
Total Amount 4.6 L (4.9 US qt) – – –
Radiator Cap
Relief Pressure 93 ~ 123 kPa – – –
(0.95 ~ 1.25 kgf/cm², 14 ∼ 18 psi)
Thermostat
Valve Opening Temperature 81 ~ 84°C (178 ~ 183°F) – – –
Valve Full Opening Temperature 95°C (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 radiators. The
thermostat 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 radiators.
Always maintain a 50% solution of phosphate free antifreeze at all times for adequate heat dissipa-
tion, lubrication and protection from freezing.
1. Water Pump
2. Thermostat
3. Air Bleed Bolt
4. Reservoir Tank
5. Front Radiator
6. Front Radiator Cap
7. Rear Radiator
8. Rear Radiator Cap
9. Drain Bolts
4-6 COOLING SYSTEM
Coolant
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room of ambi-
ent temperature).
CAUTION
Do not check the level through the coolant filler by
removing the pressure relief valve cap. If the cap
is removed, the coolant will flow out from the reser-
voir tank.
• Open the front cargo hood.

• Check the coolant level in the reservoir tank [A] with the
vehicle parked on a level surface.
If the coolant level is lower than the L (Low) level line [C],
remove the reservoir tank cap [B], then add coolant to the
F (Full) level line [D].
CAUTION
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 can 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 reservoir tank
has run completely dry; there is probably leakage in
the cooling system. Check the system for leaks.
Coolant Draining
• Refer to the Cooling System in the Periodic Maintenance
chapter.
Coolant Filling
chapter.
COOLING SYSTEM 4-7
Water Pump
Water Pump Removal
• Remove:
Coolant (drain, see Periodic Maintenance chapter)
Fan Belt Cover (see Periodic Maintenance chapter)
Fan Mounting Bolts [A]
Fan [B]
Spacer [C]
Water Pump Pulley [D] with Fan Belt
• Loosen:
Fan Belt Adjusting Bracket Bolt [A]
• justing bracket
Remove the bracket bolt [B], and move the fan belt ad-
[C] forward.
• Remove:
Water Pump Hoses [A]
Water Pump Mounting Nuts [B]
Water Pump Mounting Bolts [C]
Water Pump [D] and Bracket [E]
If necessary, remove the thermostat housing cap [F] and
coolant inlet [G].
Water Pump Installation

• Install:
New Gasket
Water Pump and Bracket
• Tighten:
Torque - Water Pump Mounting Bolts and Nuts: 20 N·m (2.0
kgf·m, 14 ft·lb)
• Install:
Coolant Inlet and New Gasket
Thermostat Housing Cap and New gasket
Water Pump Pulley
Fan Belt Adjusting Bracket
Alternator and Fan Belt (see Electrical System chapter)
Fan
• Tighten:
Torque - Coolant Inlet Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Thermostat Housing Cap Bolts: 7.8 N·m (0.80
kgf·m, 69 in·lb)
Alternator Adjusting Bracket Bolts: 20 N·m (2.0
kgf·m, 14 ft·lb)
ft·lb)
Fan Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
4-8 COOLING SYSTEM
Water Pump
Water Pump Inspection
• Check the drainage outlet passage [A] at the top and bot-
tom of the water pump body for coolant leakage.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passages. Re-
place the water pump unit.
• Remove the water pump pulley [A], and check it.

If the pulley is bent or damaged, replace the pulley.
• Check the water pump bearings by rotating pulley flange

by hand.
○Make sure pulley rotates smoothly.
If the water pump shows evidence of the bearings are
rough, replace the water pump unit.
COOLING SYSTEM 4-9
Radiator and Radiator Fan
Radiator Removal
WARNING
The radiator fans are connected directly to the bat-
tery. The radiator fans may start even if the main
switch is off. NEVER TOUCH THE RADIATOR FANS
UNTIL THE RADIATOR FAN CONNECTORS ARE
DISCONNECTED. TOUCHING THE FANS BEFORE
THE CONNECTORS ARE DISCONNECTED COULD
CAUSE INJURY FROM THE FAN BLADES.
Front Radiator
• Remove:
Coolant (drain)
Cargo Hood
Cargo Hood Stopper Bracket Bolts [A]
Cargo Hood Stopper Bracket [B]
Front Cover (see Frame chapter)
• Remove:
Water Hose [A]
Radiator Fan Switch Lead Connectors [B]
Radiator Mounting Bolts [C]
• Remove:
Fan Lead Connectors [A]
• Remove:
Water Hose [A]
Radiator Mounting Bolts [B]
Radiator with Screen [C]
• Pull out the radiator upward.

4-10 COOLING SYSTEM
• Remove:
Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
Rear Radiator
•Tilt up the seat.
•Remove:
Coolant (drain)
Seat Cover (see Frame chapter)
Radiator Fan Switch Leads Connectors [A]
Water Hose [B]
Band (cut)
Radiator Fan Lead Connectors [C]
• Remove:
Radiator Mounting Bolts [B]
• Remove:
Water Hose [A]
• Remove:
Screen Mounting Screws [A]
Screen [B]
Lower Radiator Mounting Bolts [C]
• Remove the radiator [D] downward.
COOLING SYSTEM 4-11
• Remove:
Radiator Fan Bracket [A]
Radiator Fan Mounting Bolts [B]
Radiator Fan [C]
CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
Radiator Inspection
• Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparable de-
formed fins, replace the radiator.
Radiator Cleaning
chapter.
Radiator Cap Inspection
• Check the condition of the radiator cap valve seals [A] and
valve spring [B].
If any one of them shows visible damage, replace the cap.
• Install the front radiator cap [A] on a cooling system pres-

sure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leakage.
• 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. The relief valve must open within the specified
range.
Front Radiator Cap Relief Pressure
Standard: 93 ~ 123 kPa (0.95 ~ 1.25 kgf/cm²,
14 ~ 18 psi) for 6 seconds.
If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace the cap.
4-12 COOLING SYSTEM
Thermostat
Thermostat Removal
• Open the cargo bed.
• Coolant (drain)
Remove:
Water Temperature Warning Light Switch Wire Connec-

tor [A]
Thermostat Housing Cap Bolts [B]
Thermostat Housing Cap [C]
• Remove:
Locating Screw [A]
Thermostat [B]
Thermostat Installation
• Install:
Locating Screw
New Gasket
• Tighten:
Torque - Thermostat Housing Cap Bolts: 7.8 N·m (0.80
kgf·m, 69 in·lb)
• Adjust:
Coolant (see Coolant Filling)
Thermostat Inspection
• Remove the thermostat, and inspect the thermostat valve
[A] at room temperature.
If the valve is open, replace the thermostat.
• To check valve opening temperature, suspend the ther-

mostat in a container of water and raise the temperature
of the water.
If the measurement is out of the specified range, replace
the thermostat.
Thermostat Valve Opening Temperature
Standard: 81 ~ 84°C (178 ~ 183°F)
Thermostat Valve Fully Opening Temperature

Standard: 95°C (203°F)
○The thermostat [A] must be completely submerged and
must not touch the container sides or bottom. Suspend an
accurate thermometer [B] in the water. It must not touch
the container, either.
COOLING SYSTEM 4-13
Hoses and Pipes
Hose and Pipe Installation
• Install the hoses and pipes being careful to follow bend-
ing direction or diameter. Avoid sharp bending, kinking,
flattening, or twisting.
•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.
○The clamp screws should be positioned correctly to pre-
vent the clamps from contacting anything.
Hose Inspection
• Refer to the Radiator the Cooling System in the Periodic
4-14 COOLING SYSTEM
Radiator Fan Switch, Water Temperature Warning Light Switch
Radiator Fan Switch Removal
CAUTION
The fan switch or the water temperature warning
light switch should never be allowed to fall on a
hard surface. Such a shock to their parts can dam-
age them.
• Drain the coolant (see Coolant Draining).

• Turn over
Open the cargo hood.
• Remove: the rubber cover [A].
• Radiator Fan Switch Lead Connectors [B]
Front Radiator Fan Switch [C]
• Remove:
Screws [A]
Seat Lower Cover [B]
• Turn over the rubber cover [A].

• Radiator Fan Switch Lead Connectors [B]
Remove:
Rear Radiator Fan Switch [C]
Water Temperature Warning Light Switch Removal

• Remove:
Water Temperature Warning Light Switch Lead Connec-
tor [A]
Water Temperature Warning Light Switch [B].
COOLING SYSTEM 4-15
Radiator Fan Switch, Water Temperature Warning Light Switch
Radiator Fan Switch, Water Temperature Warning
Light Switch Installation
• Apply grease to the O-ring on the fan switch.
• Apply a non-permanent locking agent to the threads of
the water temperature warning light switch.
• Tighten the fan switch and water temperature warning
light switch.
Torque - Radiator Fan Switch: 25 N·m (2.5 kgf·m, 18 ft·lb)
Water Temperature Warning Light Switch: 27 N·m
(2.8 kgf·m, 20 ft·lb)
Radiator Fan Switch, Water Temperature Warning

Light Switch Inspection
• Refer to the Switches section in the Electrical System
chapter.
ENGINE TOP END 5-1
Engine Top End

Table of Contents
Exploded View........................................................................................................................ 5-2
Specifications ......................................................................................................................... 5-4
Special Tools .......................................................................................................................... 5-5
Cylinder Head......................................................................................................................... 5-7
Cylinder Compression Measurement................................................................................ 5-7
5
Cylinder Head Removal .................................................................................................... 5-8
Cylinder Head Installation ................................................................................................. 5-9
Cylinder Head Warp.......................................................................................................... 5-10
Rocker Shaft and Rocker Arm................................................................................................ 5-11
Rocker Arm Components Removal .................................................................................. 5-11
Rocker Arm Components Installation ............................................................................... 5-11
Rocker Arm Components Disassembly ............................................................................ 5-11
Rocker Arm Components Assembly ................................................................................. 5-12
Rocker Arm/Shaft Wear .................................................................................................... 5-12
Valve Lifters ............................................................................................................................ 5-13
Valve Lifter Removal ......................................................................................................... 5-13
Valve Lifter Installation ...................................................................................................... 5-13
Valve Lifter Inspection....................................................................................................... 5-13
Valves ..................................................................................................................................... 5-14
Valve Clearance Inspection .............................................................................................. 5-14
Valve Clearance Adjustment............................................................................................. 5-14
Valve Removal .................................................................................................................. 5-14
Valve Installation ............................................................................................................... 5-14
Valve Guide Removal ....................................................................................................... 5-14
Valve Guide Installation .................................................................................................... 5-15
Valve Seat Inspection ....................................................................................................... 5-15
Valve Seat Repair ............................................................................................................. 5-15
Valve Spring Free Length ................................................................................................. 5-20
Valve Head Thickness ...................................................................................................... 5-20
Valve Stem Diameter ........................................................................................................ 5-20
Valve Guide Inspection ..................................................................................................... 5-20
Measuring Valve/Guide Clearance ................................................................................... 5-21
Valve Stem Cap Inspection............................................................................................... 5-21
Exhaust Pipe and Muffler ....................................................................................................... 5-22
Exhaust Pipe Removal...................................................................................................... 5-22
Muffler Removal................................................................................................................ 5-22
Exhaust Pipe and Muffler Installation................................................................................ 5-22
Exhaust Pipe and Muffler Inspection ................................................................................ 5-22
Spark Arrester Cleaning.................................................................................................... 5-22
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Rocker Arm Components Mounting Nuts 20 2.0 14
2 Valve Adjusting Screw Locknuts 11 1.1 95 in·lb
3 Cylinder Head Cover Nuts 5.4 0.55 48 in·lb
4 Exhaust Manifold Mounting Nuts 20 2.0 14
5 Cylinder Head Bolts 34 3.5 25 O, S
6 Stay Rod Rear Bolt 88 9.0 65
7 Inlet Manifold Mounting Nuts 7.8 0.80 69 in·lb
8 Inlet Manifold Mounting Bolts 7.8 0.80 69 in·lb
9 Muffler Mounting Bolts – – – L
10 Water Pump Mounting Studs – – – L
O: Apply engine oil.
S: Follow specified tightening sequence.
5-4 ENGINE TOP END
Specifications

Cylinder Head
Cylinder Compression 3 330 kPa (34.0 kgf/cm², 2 990 kPa (30.5 kgf/cm²,
483 psi) @300 r/min (rpm) 434 psi)
@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 (When cold) 0.2 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 45°, 32°, 60° – – –
Valve Spring Free Length 30.7 mm (1.2087 in.) 29.7 mm (1.1693 in.)
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 in.)
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° - 30:
57001-144 57001-1123
Valve Guide Arbor, 5.5: Valve Seat Cutter Holder, 5.5:

57001-1021 57001-1125
Valve Seat Cutter, 45° - 27.5: Valve Seat Cutter Holder Bar:
57001-1114 57001-1128
Valve Seat Cutter, 32° - 28: Compression Gauge Adapter:

57001-1119 57001-1431
Valve Seat Cutter, 30° - 30: Valve Guide Driver:

57001-1120 57001-1432
5-6 ENGINE TOP END
Special Tools
Valve Spring Compressor:
57001-1433
ENGINE TOP END 5-7
Cylinder Head
Cylinder Compression Measurement
• tween the piston
Thoroughly warm up the engine so that the engine oil be-
and the cylinder wall will help seal com-
pression as it does during normal running.
• 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
-1431
• Wrap a tape around the glow plug wire (Black/White) end
to insulate.
• Remove:
Fuel Cut Solenoid Wire Connector [C]
• pression
Using the starter motor, turn the engine over until the com-
gauge stops rising; this is the highest compres-
sion reading obtainable.
Cylinder Compression
Standard: 3 330 kPa (34.0 kgf/cm², 483 psi)
@300 r/min (rpm)
Service Limit: 2 990 kPa (30.5 kgf/cm², 434 psi)
@300 r/min (rpm)
• Repeat the measurement on the other cylinders.

The following table should be consulted if the obtainable compression reading is not within the spe-
cific range.
Problem Diagnosis Remedy (Action)
Cylinder compression 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
thickness of the proper thickness.
Cylinder compression Gas leakage around cylinder Replace damaged gasket and
lower than service limit head check cylinder head warp.
Bad condition of valve seating Repair if possible.
Incorrect valve, piston/cylinder Adjust.
clearance
Inspect cylinder and liner and
Piston seizure
replace/
repair as necessary.
Bad condition of piston ring
Replace.
and/or
piston ring grooves
5-8 ENGINE TOP END
Cylinder Head
Cylinder Head Removal
• Remove:
Coolant (drain)
Water Pump (see Cooling System chapter)
Exhaust Pipe (see Exhaust Pipe Removal)
Glow Plug Caps
Glow Plug Wires [A]
Glow Plug Connecting Plate
Breather Hose [B]
Fuel Injection Pipes [C]
Cylinder Head Cover Nuts [D]
Cylinder Head Cover [E]
• Remove the coolant from the cylinder head, using a

syringe [A] or some other suitable device, through the
coolant inlet opening [B].
○Insert the gauge tube [C] 10 ~ 11 cm (3.9 ~ 4.3 in.) from
the opening.
○Pull the handle slowly to pump out the coolant until the
coolant no longer comes out.
• Remove:
Rocker Arm Components (see Rocker Arm Components
Removal)
Rocker Arm Push Rods [A]
○Mark the push rods so that they may be installed in their
original positions.
•Remove:
Valve Stem Caps [B]
• Remove the cylinder head bolts following loosening se-

quence [1∼14].
• Remove:
Cylinder Head
Cylinder Head Gasket
ENGINE TOP END 5-9
Cylinder Head
Cylinder Head Installation
• Clean
cylinder.
the mating surface of the cylinder head and the
• Install:
Dowel Pins [A]
New Cylinder Head Gasket [B]
• Apply oil:
Cylinder Head Bolts
• Tighten the cylinder head bolts in the order shown.
Torque - Cylinder Head Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Apply engine oil and install:

Rocker Arm Push Rods [A] (in original locations if
reused)
○Face the recessed end [B] upward.
• Install:
Valve Stem Caps
Rocker Arm Components (see Rocker Arm Components
Installation)
• Check:
Valve Clearance (see Valve Clearance Inspection)
• Install:
Water Pump (see Cooling System chapter)
Fan Belt (see Electrical System chapter)
Fan Belt Cover (see Cooling Fan Belt Inspection in the
Fuel Injection Pipes
Cylinder Head Cover
Torque - Cylinder Head Cover Nuts: 5.4 N·m (0.55 kgf·m, 48
in·lb)
5-10 ENGINE TOP END
Cylinder Head
• Install:
Breather Hose [A] and Clamps [B]
○Twist the breather hose so that the white marks [C] face
upward and the center part is higher than both ends.
• Install:
Glow Plug Wires
Exhaust Pipe
Cylinder Head Warp

• Lay a straightedge [A] across the lower surface, intake
and exhaust manifold mounting surface of the head at
several different points, and measure warp by inserting
a thickness 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
ENGINE TOP END 5-11
Rocker Shaft and Rocker Arm
Rocker Arm Components Removal
• Remove:
Breather Hose [A]
Cylinder Head Cover Bolts [B] and Washers [C]
• Remove:
Fan Belt Cover (see Cooling System in the Periodic
Maintenance chapter)
•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.
○Check that the rocker arms at #1 cylinder are free.
If not, turn the pulley one more turn to free the rocker
arms.
• Remove:
Rocker Arm Components Mounting Nuts [A] and Wash-
ers [B]
Rocker Arm Components [C]
Rocker Arm Components Installation

• Install:
Rocker Arm Components
Washers and Rocker Arm Components Mounting Nuts
Torque - Rocker Arm Components Mounting Nuts: 20 N·m
(2.0 kgf·m, 14 ft·lb)
Rocker Arm Components Disassembly

• Remove:
Rocker Arm Components
Circlips [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
5-12 ENGINE TOP END
Rocker Shaft and Rocker Arm
• Remove:
Rocker Arms [A]
Rocker Arm Supports [B]
Washers [C]
Springs [D]
Set Bolt [E]
Rocker Shaft [F]
Rocker Arm Components Assembly

All Components
• Small grooves next to oil holes [A] in the rocker shaft [B]
must face down.
• Install the center rocker arm support [C] as shown, and
tighten the set screw.
[D] Left Lower Oil Hole
• 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

• Measure the inside diameter of the rocker arm.
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.)
• Measure the diameter of the rocker shaft.

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.)
ENGINE TOP END 5-13
Valve Lifters
Valve Lifter Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Valve Lifters [A]
○Mark and record the valve lifter locations so that they can
be installed in their original positions.
Valve Lifter Installation

• Apply engine oil and install:
Valve Lifters (original positions)
Valve Lifter Inspection
• Measure the outside diameter of the valve lifters [A].
If the valve lifter has worn past the service limit, replace
the lifter.
Valve Lifter Outside Diameter
Standard: 17.98 mm (0.7079 in.)
5-14 ENGINE TOP END
Valves
Valve Clearance Inspection
• Refer to the Engine Top End in the Periodic Maintenance
chapter.
Valve Clearance Adjustment
chapter.
Valve Removal
• Remove the cylinder head (see Cylinder Head Removal).
•○Mark andthe
Remove valve stem cap.
record the valve stem cap locations so they can
be installed in their original positions.
• Using the valve spring compressor [A] remove the split
keepers.
Special Tool - Valve Spring Compressor: 57001-1433
• Remove:
Retainer
Valve Spring
Valve
• Remove:
[A] Spring Seat
[B] Oil Seal
Valve Installation
• Replace the oil seal [A] with a new one.
• Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
• Install:
Oil Seal
[B] Valve
[C] Spring Seat
[D] Valve Spring
[E] Retainer
[F] Split Keepers
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
Spring Seat
Oil Seal
• Hammer lightly on the valve guide arbor [A] to remove the
guide from the top of the head.
Special Tool - Valve Guide Arbor, 5.5: 57001-1021
ENGINE TOP END 5-15
Valves
Valve Guide Installation
• Apply
tion.
oil to the valve guide outer surface before installa-
• Press the valve guide [A] in from the top of the head us-
ing the valve guide driver [B] until the driver bottoms on
cylinderhead.
Special Tool - Valve Guide Driver: 57001-1432
Valve Seat Inspection

• Remove the valve (see Valve Removal).
• Push the valve
Coat the seat with machinist’s dye.
• Rotate the valveinto
valve the guide.
• Pull the valve out,against the seat with a lapping tool.
• valve head. It must be the correct
and check the seating pattern on the
width [E] and even all
the way around.
NOTE
○The valve stem and guide must be in good condition, or
this check will not be valid.
If the valve seating pattern is not correct, repair the seat.
• Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter of the valve seating pattern is too
large or too small, repair the seat.
Valve Seating Surface [A] Too Wide [G]
Valve [B] Too Narrow [H]
Valve Seat [C] Uneven [J]
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.)
Valve Seat Repair

• Follow the manufacturer’s instructions for use of valve
seat cutters.
Special Tools - Valve Seat Cutter, 45° - 27.5: 57001-1114
[IN]
Valve Seat Cutter, 32° - 28: 57001-1119
[EX]
Valve Seat Cutter, 30° - 30: 57001-1120
[EX]
Valve Seat Cutter, 60° - 30: 57001-1123 [IN]
Valve Seat Cutter Holder, 5.5: 57001-1125
Valve Seat Cutter Holder Bar: 57001-1128
If the manufacture’s instructions are not available, use the
following procedure.
5-16 ENGINE TOP END
Valves
Seat Cutter Operating Cares
1. The valve seat cutter is designed only for valve seat re-
pair. Therefore the cutter must not be used for other
purposes.
2. Do not drop or hit the valve seat cutter, or the diamond
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
○Do 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 with one hand. Do not apply too much force
to the diamond portion.
NOTE
○Prior to grinding, apply oil to the cutter, and during the
operation wash off any ground particles sticking to the
cutter with washing oil.
5. After use wash the cutter with washing oil and apply a
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.
60º Cutter angle [B]
37.5 Outer diameter of cutter [C]
Operating Procedures
•Clean the seat area carefully.
•Coat the seat with machinist’s dye.
•Fit a 45° cutter to the holder and slide it into the valve
guide.
•Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
CAUTION
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.
Widened Width [A] of engagement by machining with 45º
cutter
Ground Volume [B] by cutter 32º [C]
Correct Width [D]
Ground Volume [E] by 60º cutter
60º [F]
ENGINE TOP END 5-17
Valves
• Measure the outside diameter of the seating surface with

a vernier caliper.
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
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter of the seating surface is too large,
make the 32° grind described below.
If the outside diameter [A] of the seating surface is within
the specified range, measure the seat width as described
below.
• Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter to the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
CAUTION
The 32° cutter removes material every quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat outside di-
ameter measurement step above.
• To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
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.
5-18 ENGINE TOP END
Valves
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
• Grind the seat at a 60° angle until the seat width is within
the specified range.
○To make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width mea-
surement step above.
Correct Width [B]
• Lap the valve to the seat, once the seat width and outside
diameter are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
[A] Valve
[B] Valve Seat
[C] Lapper
• The seating area should be marked about in the middle

of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part.
• Be sure to remove all grinding compound before assem-
bly.
• When the engine is assembled, be sure to adjust the valve
clearances (see Valve Clearance Adjustment).
ENGINE TOP END 5-19
Valves
5-20 ENGINE TOP END
Valves
Valve Spring Free Length
• Measure the valve spring free length.
If the free length is less than the service limit, replace the
valve spring with a new one.
Valve Spring Free Length
Valve Head Thickness

• Measure the thickness [A] of the valve head.
If the valve head thickness is less than the service limit,
replace the valve with a new one.
Valve Head Thickness
Valve Stem Diameter

• Measure the diameter of the valve stem at specified dis-
tance from end of valve as shown.
If 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 (0.2348 ~ 0.2354 in.)
Valve Guide Inspection

• Measure the inside diameter of the valve guide.
If the valve guide has worn past the service limit, replace
the valve guide or cylinder head.
Valve Guide Inside Diameter
Standard: 6.000 ~ 6.015 mm (0.2362 ~ 0.2368 in.)
○Measure the outside diameter of the valve guide re-
moved.
If the diameter is 11.05 mm (0.4350 in.), replace it with a
replacement valve guide.
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
Valves
Measuring Valve/Guide Clearance
• 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

• Visually inspect the valve stem cap [A] for wear.
If the cap is worn, replace it.
5-22 ENGINE TOP END
Exhaust Pipe and Muffler
Exhaust Pipe Removal
• Remove:
Screws [A]
Exhaust Pipe Cover [B]
Exhaust Pipe Holder Nuts [C]
• Remove:
Joint Bolts [A]
Exhaust Pipe [B]
Muffler Removal
• Remove:
Joint Bolts [A]
Muffler Mounting Bolts [B]
Muffler [C]
Exhaust Pipe and Muffler Installation

• Apply a non-permanent locking agent:
Muffler Mounting Bolts
• Check the exhaust gasket and the muffler connecting
gasket for signs of damage. If necessary, replace them
with new ones.
• After installation, thoroughly warm up the engine, wait un-
til the engine cools down, and then retighten the clamp
bolt and holder nuts.
Exhaust Pipe and Muffler Inspection
• Before removing, check for signs of leakage at the ex-
haust pipe gasket in the cylinder head and at the muffler
joint.
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.
• 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
chapter.
CONVERTER SYSTEM 6-1
Converter System
Table of Contents
Exploded View (KAF950-B1)............. 6-2 Drive Belt Inspection .................... 6-20
Exploded View (KAF950-B2 ∼, B6F Drive Belt (KAF950-B2 ∼ , B6F ∼) ..... 6-21
∼)..................................................... 6-6 Drive Belt Removal ...................... 6-21
Specifications .................................... 6-10 Drive Belt Installation ................... 6-21
Special Tools ..................................... 6-11 Drive Belt Inspection .................... 6-22
Air Cleaner......................................... 6-13 Drive Belt Deflection Inspection ... 6-22
Air Cleaner Housing Removal...... 6-13 Drive Belt Deflection Adjustment . 6-22 6
Air Cleaner Element Removal...... 6-13 Drive Pulley (KAF950-B1) ................. 6-23
Air Cleaner Element Drive Pulley Disassembly ............ 6-23
Cleaning/Inspection................... 6-13 Drive Pulley Assembly ................. 6-23
Torque Converter (KAF950-B1)......... 6-14 Drive Pulley Inspection ................ 6-25
Drive and Driven Pulley Removal 6-14 Bushing Installation...................... 6-26
Drive and Driven Pulley Drive Pulley (KAF950-B2 ∼, B6F ∼)... 6-28
Installation ................................. 6-15 Drive Pulley Removal................... 6-28
Torque Converter Inner Cover Drive Pulley Disassembly ............ 6-28
Removal .................................... 6-16 Drive Pulley Inspection ................ 6-29
Torque Converter Inner Cover Spider Shoe Side Clearance
Installation ................................. 6-16 Adjustment ................................ 6-31
Torque Converter Case Removal. 6-17 Drive Pulley Assembly ................. 6-32
Torque Converter Case Bushing Installation...................... 6-33
Installation ................................. 6-17 Drive Pulley Installation................ 6-34
Torque Converter (KAF950-B2 ∼, Driven Pulley (KAF950-B1) ............... 6-35
B6F ∼) ............................................. 6-18 Driven Pulley Disassembly .......... 6-35
Torque Converter Cover Removal 6-18 Driven Pulley Assembly ............... 6-36
Torque Converter Cover Driven Pulley Inspection .............. 6-37
Installation ................................. 6-18 Bushing Installation...................... 6-38
Torque Converter Inner Cover Driven Pulley (KAF950-B2 ∼, B6F ∼). 6-40
Removal .................................... 6-18 Driven Pulley Removal................. 6-40
Torque Converter Inner Cover Driven Pulley Disassembly .......... 6-40
Installation ................................. 6-19 Driven Pulley Inspection .............. 6-41
Torque Converter Case Removal. 6-19 Converter Driven Pulley Shoe
Torque Converter Case Inspection.................................. 6-42
Installation ................................. 6-19 Bushing Installation...................... 6-42
Drive Belt (KAF950-B1) ..................... 6-20 Driven Pulley Assembly ............... 6-43
Drive Belt Removal ...................... 6-20 Driven Pulley Width Inspection .... 6-44
Drive Belt Installation ................... 6-20 Driven Pulley Installation.............. 6-44
6-2 CONVERTER SYSTEM
Exploded View (KAF950-B1)
Torque
N·m kgf·m ft·lb
1 Drive Pulley Bolt 93 9.5 69
2 Drive Pulley Cover Bolts 13 1.3 110 in·lb
3 Weight Holder Bolts 13 1.3 110 in·lb
4 Ramp Weight Collar Bolts 7.8 0.80 69 in·lb L
5 Roller Holder Bolts 13 1.3 110 in·lb
6 Converter Cover Bolts 4.4 0.45 39 in·lb
7 Inner Cover Bolts 4.4 0.45 39 in·lb
M: Apply molybdenum disulfide grease.
Torque
N·m kgf·m ft·lb
1 Converter Case Bolts 27 2.8 20 L
2 Driven Pulley Bolt 93 9.5 69 L
3 Driven Pulley Coupling Bolts 13 1.3 110 in·lb
Exploded View (KAF950-B2 ∼, B6F ∼)
Torque
N·m kgf·m ft·lb
1 Drive Pulley Bolt 93 9.5 69
2 Drive Pulley Cover Bolts 13 1.3 113 in·lb
3 Ramp Weight Nuts 6.9 0.7 61 in·lb
4 Spider 275 28 203 Lh
5 Converter Cover Bolts 4.4 0.45 39 in·lb S
6 Inner Cover Bolts 4.4 0.45 39 in·lb
7 Cooling Fan Cover Bolts 8.8 0.9 78 in·lb
S: Follow the specific tightening sequence.
Torque
N·m kgf·m ft·lb
1 Driven Pulley Bolt 93 9.5 69 L
2 Converter Case Bolts and Nut 27 2.8 20 L
3 Converter Case Bolts 20 2.0 14 L
4 Wear Shoe Mounting Screws 1.1 0.11 10 in·lb L
Specifications
KAF950-B1
Drive Belt
Belt Width 31.5 mm (1.24 in.) 30.0 mm (1.18 in.)
Drive Pulley
Cover Bushing Inside Diameter 39.984 ∼ 40.108 mm 40.14 mm (1.5803 in.)
(1.5742 ∼ 1.5791 in.)
Sheave Bushing Inside Diameter 42.980 ∼ 43.110 mm 43.15 mm (1.6988 in.)
(1.6921 ∼ 1.6972 in.)
Spring Free Length 69.5 mm (2.7362 in.) 66 mm (2.5984 in.)
Driven Pulley
Fixed Sheave Bushing Inside Diameter 50.075 ∼ 50.165 mm 50.20 mm (1.9764 in.)
(1.9715 ∼ 1.9750 in.)
Shaft Bushing Inside Diameter:
Small 25.000 ∼ 25.090 mm 25.13 mm (0.9894 in.)
(0.9843 ∼ 0.9878 in.)
Large 32.013 ∼ 32.103 mm 32.14 mm (1.2654 in.)
(1.2604 ∼ 1.2639 in.)
Wear Shoe Width ––– 11 mm (0.43 in.)
Spring Free Length 170 mm (6.69 in.) 148 mm (5.83 in.)
KAF950-B2 ∼, B6F ∼
Drive Belt
Belt Width 34.1 mm (1.34 in.) 32.6 mm (1.28 in.)
Drive Pulley
Cover Bushing Inside Diameter 27.985 ∼ 28.085 mm 28.12 mm (1.107 in.)
(1.1018 ∼ 1.1057 in.)
Sheave Bushing Inside Diameter 38.055 ∼ 38.155 mm 38.19 mm (1.504 in.)
(1.498 ∼ 1.502 in.)
Spring Free Length 77 mm (3.03 in.) 75.6 mm (2.98 in.)
Driven Pulley
Movable Sheave Bushing Inside 39.655 ∼ 39.965 mm 40 mm (1.57 in.)
Diameter (1.561 ∼ 1.573 in.)
Wear Shoe Width ––– 16.4 mm (0.65 in.)
Spring Free Length 137 mm (5.41 in.) 130.4 mm (5.13 in.)
Special Tools
Outside Circlip Pliers: Drive & Driven Pulley Holder:
57001-144 57001-1412
Bearing Driver Set: Drive Pulley Puller Bolt:

57001-1129 57001-1429
Clutch Holder: Driven Pulley Holder:

57001-1243 57001-1465
Flywheel Holder: Drive & Driven Pulley Holder:

57001-1313 57001-1473
Flywheel & Pulley Holder: Drive Pulley Holder:

57001-1605 57001-1548
Special Tools
Drive Pulley Wrench:
57001-1549
Air Cleaner
Air Cleaner Housing Removal
• Loosen the clamps [A] and remove the air ducts [B]
• Bracket Bolts [C], Collar and Nut
Remove:
Air Cleaner Housing [D]

• 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.
CAUTION
If dirt gets into the torque converter, excessive wear
and loss of driving power may result.
Air Cleaner Element Removal

• Remove:
Wingbolts [A]
Cap [B]
• Remove:
Air Cleaner Element [A]
• cloth into
After removing the element, stuff pieces of lint-free, clean
the air cleaner duct to keep dirt out of the torque
converter.
CAUTION
If dirt gets into the torque converter, excessive wear
and loss of driving power may result.
Air Cleaner Element Cleaning/Inspection

• Refer to the Converter System in the Periodic Mainte-
nance chapter.
Torque Converter (KAF950-B1)
Drive and Driven Pulley Removal
• Remove:
Left Rear Shock Absorber (see Suspension chapter)
Air Cleaner Housing for Torque Converter (see Air
Cleaner Housing Removal)
Screws [A]
Cover [B]
• Remove:
Converter Cover Bolts
Converter Cover [A]
• Remove:
Cooling Fan Bolts [A]
Cooling Fan Cover [B]
Drive Pulley Cover
• Using
[B].
the clutch holder [A], remove the drive pulley bolt
CAUTION
Be sure to set the clutch holder on the drive pulley
cover. If the holder is set on the spider assembly,
the assembly may break.
Special Tool - Clutch Holder: 57001-1243
• Remove:
Drive Pulley [A]
Drive Belt [B] (see Drive Belt Removal)
• Using the flywheel holder [A], remove the driven pulley

bolt [B].
Special Tool - Flywheel Holder: 57001-1313
• Remove:
Driven Pulley [C]
• Remove the inner cover bolts.

• pulley [B] will not
Pull the inner cover rear end [A] rearward, if the driven
clear it.
Loosen the damper bracket nuts [A] and move the bracket
[B] rearward, if the driven pulley will not clear it.
Drive and Driven Pulley Installation

• Install:
Driven Pulley [A]
Drive Pulley [B]
Drive Belt [C] (see Drive Belt Installation)
NOTE
○When engaging the spline on the pulleys with the spline
on the shafts, do not damage the pulley’s spline. Re-
move any burrs with a file.
• Install the stepped collar [A] and washers [B] on the drive
pulley bolt, as shown.

Driven Pulley Bolt
• Tighten:
Torque - Drive Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
Special Tools - Clutch Holder: 57001-1243
Flywheel Holder: 57001-1313
CAUTION
Be sure to set the clutch holder on the drive pulley
cover. If the holder is set on the spider assembly,
the assembly may break.
• Tighten:
Torque - Converter Cover Bolts: 4.4 N·m (0.45 kgf·m, 39
in·lb)
Torque Converter Inner Cover Removal

• Remove:
Exhaust Pipe (see Engine Top End chapter)
Converter Cover (see Drive and Driven Pulley Removal)
Inner Cover Bolts
Inner Cover [A]
• Remove the inner cover [A] as shown.
Torque Converter Inner Cover Installation

• Install:
Clamps [A] for Throttle Cable
• Tighten:
Torque - Inner Cover Bolts: 4.4 N·m (0.45 kgf·m, 39 in·lb)
Torque Converter Case Removal
• Remove:
Left Rear Wheel
Damper Bracket Nuts and Bracket [A]
Left Rear Brake Hose End [B]
Drive Pulley, Driven Pulley and Drive Belt (see Drive and
Driven Pulley Removal)
Inner Cover (see Torque Converter Inner Cover Re-
moval)
• Remove:
Converter Case Bolts [A] and Nut [B]
Converter Case [C]
Torque Converter Case Installation

• Install the each parts in the reverse order of removal.
• hose end
Bleed the brake line after ins stalling the left rear brake
(see Brakes chapter).
• case bolts.
Apply a non-parmanent locking agent to the converter
Torque - Converter Case Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)

Torque Converter (KAF950-B2 ∼, B6F ∼)
Torque Converter Cover Removal
• Lift up the cargo easy to work.
• Converter Air Cleaner Housing
Remove:
(see Converter Air
Cleaner Housing Removal)
Left Rear Wheel (see Wheels/Tires chapter)
Left Rear Shock Absorber Mounting Bolts and Nuts [A]
(while moving the frame up and down with jack)
Left Rear Shock Absorber [B]
Screws [C]
Cover [D]
• Remove
cover [B].
the converter cover bolts [A] and remove the
Torque Converter Cover Installation

• Installation is basically the reverse of removal.
Torque - Converter Cover Bolts: 4.4 N·m (0.45 kgf·m, 39
in·lb)
Torque Converter Inner Cover Removal

• Remove the converter cover (see Torque Converter
Cover Removal)
• Loosen
cover.
the clamp [A] and separate the duct [B] from the
• Remove the exhaust pipe.
• Remove the inner cover bolts [A].

• Remove the cooling fan cover bolts [B], and remove the
drive pulley cover [C].
Torque Converter (KAF950-B2 ∼, B6F ∼)
• Remove the inner cover [A] upward pushing the trim [B]
of the cover as figure.
Torque Converter Inner Cover Installation

• Install:
Clamps [A]
Exhaust Pipe
Ducts
Drive Pulley Cover
Inner Cover
Torque - Inner Cover bolts: 4.4 N·m (0.45 kgf·m, 39 in·lb)
Drive Pulley Cover bolts: 13 N·m (1.3 kgf·m, 110
in·lb)
Torque Converter Case Removal

• Remove:
Converter Cover (see Torque Converter Cover Re-
moval)
Inner Cover (see Torque Converter Inner Cover Re-
moval)
Damper Bracket Nuts and Bracket [B]
Left Rear Brake Hose End [C]
Drive Pulley and Driven Pulley and Drive Belt (see Drive
Pulley and Driven Pulley Removal)
• Remove:
Converter Case Bolts [A] and Nut [B]
Converter Case [C]
Torque Converter Case Installation

○Install the each parts in the reverse order of removal.
○Install the converter case so that the o-ring installed on
the engine cover shall be not jammed between converter
case and engine cover.
• Bleed the brake line after installing the left rear brake hose
end (see Brakes chapter).
• Apply a non-parmanent locking agent to the converter
case.
Torque - Converter Case Bolts [A]: 27 N·m (2.8 kgf·m, 20
ft·lb)
Converter Case Bolts [B]: 20 N·m (2.0 kgf·m, 14
ft·lb)
Drive Belt (KAF950-B1)
Drive Belt Removal
• Remove:
Drive Pulley (see Drive and Driven Pulley Removal)
NOTE
○Before removing, observe the direction the belt’s printed
information [A] (such as numbers) is facing so that it
may be reinstalled on the pulleys to rotate in the same
direction as originally installed.
• Remove:
Drive Belt [A]
Drive Belt Installation

NOTE
○Be sure the printed information faces the same direction
so the belt may rotate in the same direction as originally
installed. When installing a new belt, install it so that the
arrow mark [A] faces to direction of the engine rotation.

• Install:
Loop the belt over the driven pulley first.
• Drive Pulley (see Drive and Driven Pulley Installation)
Drive Belt Inspection
• Refer to Drive Belt Inspection in the Periodic Maintenance
chapter.
Drive Belt (KAF950-B2 ∼ , B6F ∼)
Drive Belt Removal
• Pull the parking brake lever up and to the rear to apply
the parking brake.
WARNING
Wear gloves to protect your hands from sharp
edges during the following steps.
• Remove the drive pulley [A] (see Drive Pulley Removal).

NOTE
○Before removing the drive belt, observe the direction
of the informations [B] (Such as manufacturers name
and arrow marks) printed on the belt so that it may be
reinstalled on the pulleys as originally.
• Lift the drive belt [C] off the driven pulley [D].
Drive Belt Installation
NOTE
○Be sure the printed information faces the same direction
so the belt rotates in the same direction as originally
installed. When installing a new belt, install it so the
printed information [A] can be read from beside vehicle.

• Install the driveover
Loop the belt the driven pulley [B].
• pulley [C] (see Drive Pulley Installation).
• 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 (KAF950-B2 ∼ , B6F ∼)
Drive Belt Inspection
nance chapter.
Drive Belt Deflection Inspection
nance chapter.
Drive Belt Deflection Adjustment
nance chapter.
Drive Pulley (KAF950-B1)
Drive Pulley Disassembly
• Remove:
Drive Pulley Cover Bolts [A]
Drive Pulley Cover [B]
• Remove:
Spring [A]
Sleeve [B]
Wear Guides [C]
Spider Assembly [D]
Spacers [E]
• Remove:
Split Washers [A]
Movable Sheave [B]
• Remove:
Ramp Weight Collar Bolts [A] and Nuts
Collars [B]
Drive Pulley Assembly

Ramp Weight Collar Bolts
• Tighten:
Torque - Ramp Weight Collar Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
• Mark [A] the fixed sheave surface at the arrow [B] on the
sheave to simplify the assembly.
• Install the split washers on the fixed sheave.
•○Install the spider assembly [A].

Align the mark on the fixed sheave and arrows [B] on the
spider assembly and the movable sheave [C].
○Hold the three weight ramps up.
• Fit the wear guides [A] into the correct position between
the spider assembly [B] and the movable sheave [C].
• Install the four spacers [A] into the groove in the spider.
• is down.sleeve [B] on the shaft so that the flanged side [C]
Put the
• Install:
Spring [A]
• semblythe[D].arrows [B] on the cover [C] and the spider as-
Align
○Be sure to align the arrows and mark [E] on the fixed
sheave (arrow on the fixed sheave).
• Tighten:
Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 110
in·lb)
Drive Pulley Inspection
If the sheave surfaces [A] appear damaged, replace the
sheaves.
• Replace any sheave which has uneven wear on the belt

contacting surface.
[A] Sheave Surface
[B] Straight Edge
If the guide bushings [A] are damaged or worn, replace

them.
Cover Bushing Inside Diameter
39.984 ~ 40.108 mm (1.5742 ~ 1.5791
Standard:
in.)
Sheave Bushing Inside Diameter

42.980 ~ 43.110 mm (1.6921 ~ 1.6972
Standard:
in.)
If the splines [A] are badly worn, replace the fixed sheave.
If the wear guides [A] are damaged or worn, replace them.
If the weights [A] are damaged or worn, replace them.

If the pivot pins [B] are damaged or worn, replace them.
If the washers [C] are damaged or worn, replace them.
If the rollers [A] are damaged or worn, replace them.

If the pins [B] are damaged or worn, replace them.
If the washers [C] are damaged or worn, replace them.
If the spring free length [A] is shorter than the service limit,
replace the spring.
Spring Free Length
Bushing Installation
• Press the cover bushing [A] into the cover [B] with a suit-
able driver until it stops at the shoulder in the hole.
• Press the sheave bushing [A] into the movable sheave [B]
with a suitable driver until it stops at the shoulder in the
hole.
Drive Pulley (KAF950-B2 ∼, B6F ∼)
Drive Pulley Removal
• Remove:
Converter Covers (see Torque Converter Cover and In-
ner Cover Removal)
• Remove the three bolts of the drive pulley long nose
cover.
• Install the drive pulley holder [A] and tighten it with the
three Allen bolts [B] as shown.
Special Tool - Drive Pulley Holder: 57001-1548
• Loosen the drive pulley bolt [C].
• 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

• Hold the drive pulley holder [A] and drive & driven pulley
holder [B] in a vise.
Special Tools - Drive & Driven Pulley Holder: 57001-1473
Drive & Driven Pulley Holder: 57001-1412
• Set the pulley onto the pulley holder.

• Drive Pulley Cover Bolts [A]
Remove:
Drive Pulley Cover [B]
• Remove:
Spring [A]
Spacer
• Put the drive pulley wrench [A] on the spider [B] and
tighten the bolt [C].
Special Tool - Drive Pulley Wrench: 57001-1549
• Turn the wrench counterclockwise and remove the spider
with the movable sheave.
• Remove:
Spider [A]
Shoes [B]
Nuts [C]
Ramp Weight Pin [D]
Ramp Weight [E]
Movable Sheave [F]
Fixed Sheave [G]
Drive Pulley Inspection

sheaves.

contacting surface.
Seave Surface [A]
Straight Edge [B]
If the cover bushing is damaged or worn, replace the drive
pulley cover.
Cover Bushing Inside Diameter [A]
Standard: 27.985 ∼ 28.085 mm (1.1018 ∼ 1.1057
in.)
If the sheave bushing is damaged or worn, replace it.

Sheave Bushing Inside Diameter [A]
Standard: 38.055 ∼ 38.155 mm (1.4982 ~ 1.5022
in.)
If the spider shoes [A] are damaged, replace them.

• Check the spider shoe side clearance (see Spider Shoe
Side Clearance Inspection).
If the ramp weights [A] are damaged or worn, replace

them.
If the pins [B] are damaged or worn, replace them.
If the rollers [A] are damaged or worn, replace the spider

[B].
If the washers [C] are damaged or worn, replace the spi-
der.
If the spring is worn or damaged, replace the spring.
Spring Free Length [A]
Standard: 77 mm (3.03 in.)
Spider Shoe Side Clearance Adjustment

• Remove:
Drive Pulley (see Torque Converter Removal)
Drive Pulley Cover and Spring (see Drive Pulley Disas-
sembly)
• Temporarily install:
Dowel Pins (2)
Drive Pulley Cover
Two Bolts (at dowel pins)
• Turn the movable sheave clockwise.

• and the post
Measure the resulting clearance [A] between the shoe [B]
[C] on the movable sheave at all four arms.
Shoe Side Clearance
Standard: 0.05 ~ 0.20 mm (0.0020 ~ 0.0079 in.)
If any of the measurements are greater than the max-
imum, replace all shoes with standard shoes (P/No.
49048-1090) (see Drive Pulley Disassembly).
• Turn the movable sheave clockwise.

• and the post
Measure the resulting clearance [A] between the shoe [B]
[C] on the movable sheave at two positions
as shown.
[D] Arrow Mark
If the clearance is not within the specified range, adjust it
according to following chart.
Present Shoes
Clearance Measurement
Part Number Thickness
7.2 mm
49048-1078
(0.283 in.)
7.3 mm
up to 0.05 mm (0.0020 in.) 49048-1079
(0.287 in.)
7.4 mm
49048-1089
(0.291 in.)
over 0.05 to 0.20 mm no change
(over 0.0020 to 0.0079 in.) 49048-1090 7.5 mm
(standard clearance) (0.295 in.)
7.6 mm
49048-1091
(0.299 in.)
7.7 mm
49048-1092
(0.303 in.)
7.8 mm
over 0.20 mm (0.0079 in.) 49048-1093
(0.307 in.)
7.9 mm
49048-1094
(0.311 in.)
8.0 mm
49048-1095
(0.315 in.)
• Check that the movable sheave [A] moves smoothly, after

the shoe side clearance adjustment.
○The movable sheave must move freely towards the fixed
sheave [B].
If the movable sheave does not move smoothly, readjust
the shoe side clearance.
Drive Pulley Assembly

• Install the ramp weight [A] as shown.
• Tighten:
Torque - Ramp Weight Nuts [B]: 6.9 N·m (0.7 kgf·m, 61 in·lb)
• Check that the ramp weights swing smoothly.
• Hold the fixed sheave [A] with the drive pulley holder [B]
in a vise.
Special Tool - Drive & Driven Pulley Holder: 57001-1473
• Clean the threads of the fixed sheave and spider.

• Movable Sheave
Install:
Spider [A] and Wear Shoes [B]

○Align the arrow [C] on the spider with the arrow [D] on the
movable sheave.
○Insert the shoes so that the rubber side faces inward.
• Put the drive pulley wrench [A] on the spider [B] and
tighten the bolt [C].
Special Tool - Drive Pulley Wrench: 57001-1549
• Turn the wrench for tightening.
Torque - Spider: 275 N·m (28 kgf·m, 203 ft·lb)
• Put the spring [A] in the groove of the spider.

• Install:the arrows [B] on the drive pulley cover and spider.
Align
• Dowel Pins [C]
Drive Pulley Cover [D]
• Tighten:
Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 113
in·lb)
• Clean
fluid.
the surface of the sheaves with an oil-less cleaning
• 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
• 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.
Drive Pulley Installation

• Clean the following portions with an oil-less cleaning fluid
such as trichloroethylene or acetone.
Fixed Sheave Tapered Portion [A]
Crankshaft Tapered Portion [B]
WARNING
These cleaning fluids are usually highly flammable
and harmful if breathed for prolonged periods. Be
sure to heed the fluid manufacturer’s warnings.
• Install the drive pulley, and screw in the drive pulley bolt
with the stepped collar [A] and washers (2) [B] as shown.
• Hold the drive pulley with the drive pulley holder [A].
• Tighten:
Torque - Drive Pulley Bolt [B]: 93 N·m (9.5 kgf·m, 69 ft·lb)
• Install converter inner cover (see Torque Converter inner

cover Installation).
• Install the drive pulley long nose cover.
Torque - Cooling Fan Cover Bolts: 8.8 N·m (0.9 kgf·m, 78
in·lb)
Driven Pulley (KAF950-B1)
Driven Pulley Disassembly
• Make the driven pulley holder as shown if necessary.
[A] Wooden Board: 500 × 500 × 10 mm (19.7 × 19.7 ×
0.4 in.)
[B] Radius: 80 mm (3.15 in.)
[C] Bolts: 6 mm (0.24 in.) dia., 30 mm (1.18 in.) length
[D] Stopper Pin: 8 mm (0.31 in.) dia., 25 mm (0.98 in.)
length
[E] Wire: 140 mm (5.5 in.) length
[F] 130 mm (5.1 in.)
[G] 150 mm (5.9 in.)
• Remove:
Coupling Bolts [A]
Coupling [B]
NOTE
○Do not loosen the coupling inside bolts [C]. The shaft
hub [D] and the coupler plate [E] are balanced at the
factory.
• Disassemble the driven pulley in accordance with the fol-

lowing procedures.
1. Set the driven pulley on the driven pulley holder.
2. Turn the fixed sheave [A] counterclockwise about 45°.
3. Hold the fixed sheave with the stopper pin [B].
4. Press the ramp cap [C].
5. Remove the circlip [D].
6. Release the fixed sheave slowly.
7. Remove the ramp cap and spring.
NOTE
○Mark and record the locations of the spring end fitting
holes [A].
Driven Pulley Assembly
• Install the spring onto the fixed sheave [A], inserting the
spring end into the hole "B" [B].
• Put the ramp cap [A] on the spring, inserting the spring
end into the hole "2" [B].
• Press the ramp cap [A] onto the movable sheave shaft
[B], aligning the arrow [C] on the ramp cap with the punch
mark [D] on the shaft.
• Turn the fixed sheave [A] counterclockwise while pressing

the ramp cap [B] until the arrow [C] on the sheave passes
over the arrow [D] on the cap.
• Hold the fixed sheave with the stopper pin [E].
• Install the new circlip [A] while pressing the ramp cap [B]
to the bottom.
NOTE
○Install the circlip so that the opening [C] is aligned with
a spline groove [D].
• Check for the alignment of the arrows [A] on the fixed

sheave [B] and the ramp cap [C].
• Install the coupling [A] so that the arrow [B] on it is aligned

with the arrow [C] on the fixed sheave [D].
• Tighten:
Torque - Driven Pulley Coupling Bolts: 13 N·m (1.3 kgf·m,
110 in·lb)
Driven Pulley Inspection

sheaves.
contacting surface.
[B] Straight Edge
If the guide bushings [C] are damaged or worn, replace
them.
Fixed Sheave Bushing Inside Diameter
Standard 50.075 ~ 50.165 mm (1.9715 ~ 1.9750
in.)
Shaft Bushing Inside Diameter (Small)

Standard 25.000 ~ 25.090 mm (0.9843 ~ 0.9878
in.)
Shaft Bushing Inside Diameter (Large)

Standard 32.013 ~ 32.103 mm (1.2604 ~
1.2639 in.)
If the splines [A] are damaged or worn, replace the ramp
cap and sheave.
If the ramps [A] or the wear shoes [B] are damaged or

worn, replace the ramp cap [C] or the shoes.
Wear Shoe Width
If the spring free length [A] is shorter than the service limit,
replace the spring.
Spring Free Length
• Press the fixed sheave bushing [A] into the fixed sheave
[B] with a suitable driver until the end of the bushing is
even with the end [C] of the hole.
• Press the large shaft bushing [A] into the movable sheave
[B] with a suitable driver until the end of the bushing is
even with the end [C] of the hole.
• Press the small shaft bushing [D] into the movable sheave
with a suitable driver until the end of the bushing is 0.2 ~
0.8 mm (0.007 ~ 0.031 in.) [E] from the end [F] of the hole.
Driven Pulley (KAF950-B2 ∼, B6F ∼)
Driven Pulley Removal
• Remove:
Torque Converter Covers (see Torque Converter Outer
and Inner Cover Removal)
Drive Pulley (see Drive Pulley Removal)
Drive Belt (see Drive Belt Removal)
• Using a flywheel & pulley holder [A], remove the driven
pulley bolt [B] and stepped collar.
Special Tool - Flywheel & Pulley Holder: 57001-1605
• Remove:
Driven Pulley
Driven Pulley Disassembly
• Hold the drive & driven pulley holder [A] in a vise.
• Screw
holder.
the guide bar [B] of the spring holder set into the
Special Tool - Spring Holder Set: 57001-1465

• Put the driven pulley [C] on the guide bar.
• Tighten the nut [D], and compress the spring with the
spring holder [E] of the spring holder set.
Special Tool - Spring Holder Set: 57001-1465
• Remove the circlip [A] with circlip pliers [B].

Special Tool - Circlip Pliers: 57001-144
• Remove the nut and spring holder [C].
• Remove:
Circlip [A]
Washer [B]
Ramp [C]
Spring [D]
Movable Sheave [E]
Spacer [F]
Fixed Sheave with Shaft [G]
• Remove:
Screws [A]
Wear Shoes [B]
Driven Pulley Inspection

sheaves.
contacting surface.
Straight Edge [B]
If the guide bushings [A] are damaged or worn, replace

the movable sheave.
Sheave Bushing Inside Diameter
Standard: 39.655 ∼ 39.965 mm (1.5612 ∼ 1.5734
in.)
If the splines of the fixed sheave and ramp [A] are dam-
aged or worn, replace them.
If the spring is damaged or worn, replace the spring.

Spring Free Length [A]
Converter Driven Pulley Shoe Inspection

nance Chapter.
• Press the movable sheave bushings [A] into the movable
sheave [B] using the special tool so that the end of bush-
ing are flush with the shoulder [C] in the holes.
Driven Pulley Assembly
• Install
figure.
the wear shoes [A] on the movable sheave [B] as
○The wear shoe shall be installed so that the mark [C] on

the shoe faces outward.
• Tighten:
Torque - Wear Shoe Mounting Screws: 1.1 N·m (0.11 kgf·m,
10 in·lb)
• Hold the fixed sheave with the drive & driven pulley holder
and driven pulley holder in a vise.
Special Tools - Drive & Driven Pulley Holder: 57001-1412
Drive Pulley Holder: 57001-1465
• Install the Spacer(s) [A] on the fixed sheave [B].
• Install:
Movable Sheave [A]
Spring [B]
○Insert the spring end in to the hole [C] on the movable
sheave.
• Install the ramp [A] on the fixed sheave shaft.

• Put the washer
Insert the spring end [B] into the hole “I” on the ramp.
•○The washer shall[C]beand circlip [D] on the ramp.
installed so that the recess of it faces
out ward.
• Install the spring holder [A].

• ramp, andflatpush
Align the portions [B] of spline of the fixed sheave and
down the ramp halfway by tightening the
flange nut [C].
• Hold the movable sheave [D] by turning it counterclock-
wise 120º and tighten the flange nut until the bottom of
ramp hits the movable sheave.
• Install the washer and circlip.
• Release the movable sheave slowly until it stops naturally.
• Inspection) driven pulley width (see Driven Pulley width
Inspect the
Driven Pulley Width Inspection
• Remove
Removal)
the converter Cover (see Converter Inner Cover
• Check the driven pulley width [A] for drive belt.

Standard: 34.65 ∼ 34.95 mm (1.36 ∼ 1.38 in.)
If the width is out of specified range, remove the driven
pulley and adjust it using the spacers [B] (see Driven Pul-
ley Removal).
Spacers
Part No. Thickness
92026-1625 1.0 mm (0.039 in.)
92026-1626 0.6 mm (0.024 in.)
92026-1627 1.4 mm (0.055 in.)
92026-1628 0.8 mm (0.031 in.)
92026-0036 0.3 mm (0.012 in.)
Driven Pulley Installation

• Clean the transmission driven shaft [A], and apply molyb-
denum grease width the specified range on it.
• Install:
Driven Pulley [B]
58 mm (2.3 in.) [C]
• Install the stepped collar[A] on the pulley as shown.

• Apply a non-permanent locking agent to the thread of

driven pulley bolt.
• Using a flywheel & pulley holder [A], tighten the driven
pulley bolt [B].
Special Tool - Flywheel & Pulley Holder: 57001-1605
Torque - Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
ENGINE LUBRICATION SYSTEM 7-1

Table of Contents
Exploded View........................................................................................................................ 7-2
Specifications ......................................................................................................................... 7-4
Special Tool and Sealant ........................................................................................................ 7-5
Engine Oil Flow Chart............................................................................................................. 7-6
Engine Oil and Oil Filter.......................................................................................................... 7-7
Oil Level Inspection........................................................................................................... 7-7
Oil and/or Filter Change.................................................................................................... 7-8
Oil Filter Removal ............................................................................................................. 7-8
Oil Filter Installation .......................................................................................................... 7-8 7
Oil Pan and Oil Strainer.......................................................................................................... 7-9
Oil Pan and Oil Strainer Removal ..................................................................................... 7-9
Oil Pan and Oil Strainer Installation .................................................................................. 7-9
Oil Strainer Cleaning/Inspection ....................................................................................... 7-9
Oil Pump................................................................................................................................. 7-10
Oil Pump Removal ............................................................................................................ 7-10
Oil Pump Installation ......................................................................................................... 7-10
Oil Pump Inspection.......................................................................................................... 7-10
Relief Valve............................................................................................................................. 7-12
Relief Valve Removal........................................................................................................ 7-12
Relief Valve Installation..................................................................................................... 7-12
Relief Valve Inspection...................................................................................................... 7-12
Oil Pressure Measurement..................................................................................................... 7-13
Oil Pressure Measurement ............................................................................................... 7-13
Oil Pressure Switch ................................................................................................................ 7-14
Oil Pressure Switch Removal ........................................................................................... 7-14
Oil Pressure Switch Installation ........................................................................................ 7-14
Oil Nozzle ............................................................................................................................... 7-15
Oil Nozzle Installation ....................................................................................................... 7-15
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Oil Pump Gear Bolt 20 2.0 14
2 Relief Valve Bolt 39 4.0 29
3 Oil Strainer Mounting Bolts 7.8 0.80 69 in·lb
4 Oil Strainer Mounting Nuts 7.8 0.80 69 in·lb
5 Oil Pressure Switch 14 1.4 10 SS
6 Oil Nozzle 9.8 ~ 18 1.0 ~ 1.8 7.2 ~ 13
7 Oil Filter Stud Bolt 44 4.5 33
8 Oil Pan Bolts And Nuts 7.8 0.80 69 in·lb
9 Engine Oil Drain Plugs 34 3.5 25
LG: Apply liquid gasket (Three Bond: 1207F).
SS: Apply silicone sealant.
Specifications

Engine Oil and Oil Filter
Engine Oil:
Grade API CF or CF-4 class – – –
Viscosity SAE 10W-40 – – –
Capacity 3 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 – – –
Oil Pump
Oil Pump Side Clearance 0.03 ~ 0.096 mm (0.0012 ~ 0.0038 0.15 mm
in.) (0.0059 in.)
Oil Pump Housing Depth 12.63 ~ 12.67 mm (0.4972 ~ 0.4988 12.72 mm
in.) (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 @3 000 r/min (rpm), 196 ~ 490 kPa – – –
Oil Temperature. 55 ∼ 65°C (131 ~ 149°F) (2.0 ~ 5.0 kgf/cm², 28 ~ 71 psi)
Special Tool and Sealant
Oil Pressure Gauge Adapter, PT 1/8:
57001-1033
Kawasaki Bond (Silicone Sealant):

56019-120
Three Bond:
1207F
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 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.
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury.
Oil Level Inspection

NOTE
○If the vehicle has just been used, wait several minutes
for all the oil to drain down.
○If 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.
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
• Park the vehicle on level ground, and tilt up the seat.

• and inserttheitdipstick
Pull out [A] out of the dipstick tube, wipe it dry,
into the tube securely.
• Pull out the dipstick and check the oil level. The oil level
should be between the upper (F) and lower (L) level marks
[A].
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 oil.
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.
[A] Oil Filler Cap
NOTE
○If 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.
CAUTION
To avoid the engine damage, do not fill the engine
oil above the full level.
Oil and/or Filter Change
• Refer to the Engine Lubrication System in the Periodic
Oil Filter Removal
Oil Filter Installation
Oil Pan and Oil Strainer
Oil Pan and Oil Strainer Removal
• Remove:
Flywheel (see End Plate Removal in Crank-
shaft/Crankcase chapter)
End Plate (see Crankshaft/Cylinder Block chapter)
• Remove:
Oil Pan Bolts [A] and Nuts [B]
Oil Pan [C]
Gasket
• Remove:
Oil Strainer Bolt [A]
Oil Strainer Nuts [B]
Oil Strainer [C]
Gasket
Oil Pan and Oil Strainer Installation

• Clean the oil strainer thoroughly whenever it is removed.
• New Oil Strainer Gasket [A]
Install:
Oil Strainer
• Tighten:
Torque - Oil Strainer Mounting Bolts and Nuts: 7.8 N·m
(0.80 kgf·m, 69 in·lb)
• Apply liquid gasket [A] to the mating surface as shown.

Sealant - Three Bond: 1207F
• Install:
New Oil Pan Gasket
Oil Pan
• Tighten:
Torque - Oil Pan Bolts and Nuts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
Oil Strainer Cleaning/Inspection

• Clean
it.
the oil strainer, and remove any particles stuck to
NOTE
○While cleaning the strainer, check for any metal parti-
cles that might indicate internal engine damage.
• Check the screen [A] carefully for any damage: holes and
broken wire.
If the screen is damaged, replace the oil strainer.
Oil Pump
Oil Pump Removal
• Remove:
Timing Gear Case (see Crankshaft/Cylinder Block chap-
ter)
Oil Pump Outer Rotor [A]
Oil Pump Installation

• Clean
gine oil.
and lubricate the oil pump outer rotor [A] with en-
• Install the oil pump outer rotor with the punch mark [B]
facing inside.
• Install:
Timing Gear Case (see Crankshaft/Cylinder Block chap-
ter)
Oil Pump Inspection

• Remove:
Timing Gear Case Cover (see Crankshaft/Crankcase
chapter)
• Set up a dial gauge [A] against the oil pump gear [B] as
shown and measure the oil pump side clearance.
Oil Pump Side Clearance
Standard: 0.03 ~ 0.096 mm (0.0012 ~ 0.0038 in.)
If the clearance exceeds the service limit, go to next pro-
cedure.
• Remove:
Oil Pump Outer Rotor (see Oil Pump Removal)
• [A] with athe
Measure depth of the pump housing in the crankcase
depth micrometer [B] at several points.
Oil Pump Housing Depth
12.63 ~ 12.67 mm (0.4972 ~ 0.4988
Standard:
in.)
If the depth exceeds the service limit, replace the
crankcase.
If the depth within the service limit, replace the timing gear
case.
Oil Pump
• Visually
[B].
inspect the oil pump inner rotor [A] and outer rotor
If there is any damage or uneven wear, replace timing

gear case [C].
Relief Valve
Relief Valve Removal
• Remove:
Engine Oil (drain)
Relief Valve Bolt [A] and Washer
Relief Valve Spring
Relief Valve Plunger
Relief Valve Installation

• Install:
Relief Valve Plunger [A]
Relief Valve Spring [B]
Washer [C] and Relief Valve Bolt [D]
• Tighten:
Torque - Relief Valve Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Relief Valve Inspection

• 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.
• Measure the relief valve spring free length.
If the spring is shorter than the standard, replace the
spring.
Relief Valve Spring Free Length
Standard: 34.5 ~ 36.5 mm (1.358 ~ 1.437 in.)
• Remove:
Oil Pressure Switch [A] (see Oil Pressure Switch Re-
moval)
• Attach a suitable gauge (10 kgf/cm²) [B] and adapter [C]
to the hole.
Special Tool - Oil Pressure Gauge Adapter, PT 1/8: 57001
-1033
• Install the parts removed.
• Run the engine at the specified speed, and read the oil
pressure gauge.
Oil Pressure
Standard: 196 ∼ 490 kPa (2.0 ~ 5.0 kgf/cm²,
28 ~ 71 psi) @3 000 r/min (rpm), oil
temperature. 55 ~ 65°C (131 ~ 149°F)

• Remove the oil pressure gauge and adapter.
WARNING
Take care against burns from hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
• Tighten the oil pressure switch (see Oil Pressure Switch

Installation).
Troubleshooting Guide
Low Oil Pressure High Oil Pressure
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
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Engine oil (drain, see Engine Oil Change)
Fuel Injection Pipes (see Fuel System chapter)
Switch Connector [A]
Oil Pressure Switch [B]
Oil Pressure Switch Installation

• Apply silicone sealant to the threads of the oil pressure
switch and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 14 N·m (1.4 kgf·m, 10 ft·lb)
Oil Nozzle
Oil Nozzle Installation
• Refer to the Timing Gear Case Installation section in the
Crankshaft/Crankcase chapter.
ENGINE REMOVAL/INSTALLATION 8-1
Table of Contents
Exploded View........................................................................................................................ 8-2
Special Tools .......................................................................................................................... 8-4
Engine Removal/Installation ................................................................................................... 8-5
Engine Removal................................................................................................................ 8-5
Engine Installation (KAF950-B1)....................................................................................... 8-6
Engine Installation (KAF950-B2 ∼, B6F ∼) ........................................................................ 8-7
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
2 Engine Bracket Bolts – – – L
3 Engine Mounting Bolts 44 4.5 33
Special Tools
Assembly Jig: Assembly Jig:
57001-1365 57001-1566
Engine Removal
• Disconnect:
Battery Terminal Leads (see Electrical System chapter)
• Remove:
Engine Oil (drain, see Engine Lubrication System chap-
ter)
Coolant (drain, see Cooling System chapter)
Coolant in Cylinder Head (see Cylinder Head Removal
in Engine Top End chapter)
Cargo Bed (see Frame chapter)
Engine Holder Stay (see Frame chapter)
Air Duct
Exhaust Pipe (see Engine Top End chapter)
Torque Converter and Case (see Torque Converter Sys-
tem chapter)
Water Hoses [A] (upper and lower)
Injection Pump Cover [B] and Cable Bracket
Fuel Hoses [C]
Throttle Cable End [D]
Shift Shaft Lever of Shift Cable and Hi/Low Cable
Water Temperature Warning Light Switch Lead Connec-
tor [E]
Glow Plug Leads [F]
Fuel Cut Valve Lead Connector [G]
Oil Pressure Switch Lead Connector [H]
Alternator Lead and Lead Connectors [I]
Dipstick
• Remove:
Starter Motor Cable [A] and Lead Connector [B]
Engine Ground Lead [C]
• Remove:
Engine Mounting Bolts [A]
• Remove:
Engine [A]
• Remove:
Engine Bracket Bolts [A]
Engine Bracket [B]
Engine Installation (KAF950-B1)

• Install the engine on the brackets.
• bracketabolts
Apply non-permanent locking agent to the engine
and tighten them.
• torque converter. mounting position for alignment of the
Adjust the engine
○Mount the engine and install the engine mounting bolts

loosely.
○Install the assembly jig [A] onto the transmission drive
shaft and crankshaft as shown.
Special Tool - Assembly Jig: 57001-1365
○Tighten the bolt [B] until the assembly jig is fitted to the
engine completely.
NOTE
○Use the driven pulley bolt [B] and the stepped collar [C]
of the drive pulley.
[D] 60 mm (2.36 in.)
○Tighten:
Torque - Engine Mounting Bolts: 44 N·m (4.5 kgf·m, 33 ft·lb)
○Remove the assembly jig.
• Adjust:
Engine Oil
Coolant
Engine Installation (KAF950-B2 ∼, B6F ∼)
• Install the engine on the brackets.
• bracketabolts
Apply non-permanent locking agent to the engine
and tighten them.
• torque converter. mounting position for alignment of the
Adjust the engine
○Mount the engine and install the engine mounting bolts

loosely.
○Install the assembly jig [A] onto the transmission drive
shaft and crankshaft as shown.
Special Tool - Assembly Jig: 57001-1566
○Screw in the bolts [B] until the assembly jig is fitted to the
transmission drive shaft. The length [C] between the jig
and the end of coupling is 5 mm (0.197 in.).
○Tighten:
Torque - Engine Mounting Bolts: 44 N·m (4.5 kgf·m, 33 ft·lb)
○Remove the assembly jig.
• Adjust:
Engine Oil
Coolant
CRANKSHAFT/CRANKCASE 9-1
Crankshaft/Crankcase
Table of Contents
Exploded View................................... 9-2 Crankshaft Main Bearing
Specifications .................................... 9-4 Insert/Journal Wear................... 9-24
Special Tools and Sealant ................. 9-6 End Plate ........................................... 9-25
Timing Gear Case ............................. 9-8 End Plate Removal ...................... 9-25
Timing Gear Case Removal......... 9-8 End Plate Installation ................... 9-26
Timing Gear Case Installation...... 9-9 Oil Seal Retainer ............................... 9-27
Timing Gear Case Cover Oil Seal Oil Seal Replacement .................. 9-27
Replacement ............................. 9-12 Pistons and Crankcase...................... 9-28
Timing Gear Inspection ................ 9-13 Piston Removal............................ 9-28
Camshaft ........................................... 9-15 Piston Installation......................... 9-28
Camshaft Removal ...................... 9-15 Crankcase Removal..................... 9-29
Camshaft Installation ................... 9-15 Crankcase Warp .......................... 9-29
Camshaft Inspection .................... 9-16 Crankcase Wear .......................... 9-30
Crankshaft and Connecting Rods...... 9-18 Piston Diameter ........................... 9-30
9
Connecting Rod Removal ............ 9-18 Piston/Cylinder Clearance ........... 9-31
Connecting Rod Installation ......... 9-18 Cylinder Boring, Honing ............... 9-31
Crankshaft Removal .................... 9-19 Camshaft Bearing Replacement .. 9-31
Crankshaft Installation ................. 9-19 Camshaft Plug Replacement ....... 9-32
Connecting Rod Big End Side Piston Ring and Ring Groove
Clearance.................................. 9-20 Wear.......................................... 9-32
Connecting Rod Inspection.......... 9-21 Piston Ring End Gap ................... 9-33
Crankshaft Inspection .................. 9-21 Piston Ring Thickness ................. 9-33
Crankshaft Side Clearance .......... 9-23 Piston and Piston Pin Wear ......... 9-33
Connecting Rod Big End Bearing
Insert/Crankpin Wear ................ 9-23
9-2 CRANKSHAFT/CRANKCASE
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Camshaft Gear Bolt 43 4.4 32
2 Camshaft Retainer Bolts 7.8 0.80 69 in·lb
3 Idle Gear Bolts 25 2.6 19
4 Oil Pump Gear Bolt 20 2.0 14
5 Fuel Injection Pump Gear Nut 64 6.5 47
6 Timing Gear Case Cover Bolts and Nuts 7.8 0.80 69 in·lb
7 Timing Gear Case Bolts 7.8 0.80 69 in·lb
8 Oil Nozzle 98 ~ 18 1.0 ~ 1.8 7.2 ~ 13
9 Crankcase Plug 25 2.5 18 L
10 Connecting Rod Cap Nuts 36 3.7 27
11 Crankshaft Pulley Bolt 98 10 72 O
12 Crankshaft Main Bearing Cap Bolts 59 6.0 43
13 Oil Seal Retainer Bolts 5.4 0.55 48 in·lb
14 End Plate Bolt 39 4.0 29
15 Coupling Bolts (KAF950-B1) 37 3.8 27 L
16 Flywheel Mounting Bolts (KAF950-B1) 44 4.5 33 LG
Flywheel With Coupling Mounting Bolts
17 44 4.5 33 L, S
(KAF950-B2 ∼, B6F ∼)
18 End Plate Seal Cover Bolts – – – LG
19 End Plate Seal Cover Studs – – – LG
20. KAF950-B1
21. KAF950-B2 ∼, B6F ∼
G: Apply grease.
LG: Apply liquid gasket (Three Bond 1207F).
S: Follow specified tightening sequence.
Specifications

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 ~ 35.955 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
– – –
(1.6526 ~ 1.6535 in.)
Crankshaft Crankpin Diameter 36.976 ~ 37.000 mm
– – –
(1.4557 ~ 1.4567 in.)
Crankshaft Out Of Round and Taper – – – 0.02 mm
(0.0008 in.)
Undersize Crankshaft Main Bearing 0.25 mm (0.0098 in.) – – –
Inserts Undersize
Crankshaft #3 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.)
Specifications

Oversize Thrust Washers 0.12 mm (0.0047 in.) – – –
Oversize
Crankshaft #3 Main Journal Width 22.00 ~ 22.07 mm – – –
(0.8661 ~ 0.8689 in.)
Connecting Rod Big End Bearing 0.020 ~ 0.044 mm 0.07 mm
Insert/crankpin Clearance (0.0008 ~ 0.0017 in.) (0.0028 in.)
Crankshaft Main Bearing 0.020 ~ 0.044 mm 0.07 mm
Insert/Journal Clearance (0.0008 ~ 0.0017 in.) (0.0028 in.)
Pistons and Crankcase
Crankcase Warp – – – 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.)
difference between any
two measurements
Valve Lifter Bore Inside Diameter 18.018 mm (0.7094 in.) 18.05 mm (0.7106 in.)
Camshaft Bearing Inside Diameter – – – 36.06 mm (1.4197 in.)
Piston Diameter 71.93 ~ 71.96 mm – – –
(2.8319 ~ 2.8331 in.)
Piston/Cylinder Clearance 0.06 ~ 0.08 mm 0.12 mm
(0.0024 ~ 0.0031 in.) (0.0047 in.)
Oversize Piston and Rings 0.25 mm (0.0098 in.) – – –
Oversize
Piston Ring/groove Clearance – – – less than 0.12 mm
(0.0047 in.)
(Top, Second and Oil Ring)
Piston Ring End Gap – – – 0.70 mm (0.0276 in.)
(Top, Second and Oil Ring)
Piston Ring Thickness:
Top 1.445 ~ 1.465 mm – – –
(0.0569 ~ 0.0577 in.)
Second 1.470 ~1.490 mm – – –
(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.)
Special Tools and Sealant
Bearing Puller Adapter: Crankcase Splitting Tool Assembly:
57001-136 57001-1098
Inside Circlip Pliers: Camshaft Bearing Driver:

57001-143 57001-1434
Piston Pin Puller Assembly: Camshaft Bearing Remover:

57001-910 57001-1435
Piston Ring Compressor Grip: Timing Gear Cover Oil Seal Driver:
57001-1095 57001-1436
Piston Ring Compressor Belt, 50 ∼ 67: Retainer Oil Seal Driver:

57001-1096 57001-1437
Flywheel Holder: Three Bond:
57001-1438 1207F
Timing Gear Case
Timing Gear Case Removal
• Remove:
Fan Belt (see Electrical System chapter)
• Using the flywheel holder [A], hold the crankshaft.
• Remove:
Crankshaft Pulley Bolt [A]
• Remove:
Crankshaft Pulley [A]
Special Tools - Crankcase Splitting Tool Assembly: 57001
-1098 [B]
Bearing Puller Adapter: 57001-136 [C]
• Remove:
Oil Pan (see Engine Lubrication System chapter)
Oil Strainer
Timing Gear Case Cover Bolts [A] and Nuts [B]
Timing Gear Case Cover [C]
Bracket [D]
•○Temporary, install the flywheel for the crankshaft holding.

Using the flywheel holder [A], hold the crankshaft.
Timing Gear Case
• Remove:
Gear Mounting Nut [A]
Gear Mounting Bolts [B]
Oil Pump Drive Gear [C]
Camshaft Drive Gear [D]
• Position the flywheel holder to the opposite side.
• Remove:
Idle Gear Mounting Bolts [E]
Thrust Plate [F]
Idle Gear [G]
• Remove:
Idle Gear Shaft [A]
• tion pump
Using a suitable bearing puller [B], remove the fuel injec-
drive gear [C].
• Remove:
Fuel Injection Pump [D] (see Fuel System chapter)
• Remove:
Camshaft Retainer Bolts [A]
Camshaft Retainer [B]
Timing Gear Case Bolts [C]
Timing Gear Case [D]
• Remove:
Oil Pump Outer Rotor [A]
Timing Gear Case Installation

• Clean and lubricate the oil pump outer rotor [A] with en-
gine oil.
• Install the oil pump outer rotor with the punch mark [B]
facing inside.
Timing Gear Case
• Install:
Dowel Pins [A]
New Timing Gear Case Gasket [B]
Timing Gear Case
○Rotate the oil pump shaft to engage oil pump rotors.
• Install:
Camshaft Retainer [A]
• Tighten:
Torque - Camshaft Retainer Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
Timing Gear Case Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
M6 × 28 mm [B]
M6 × 18 mm [C]
M6 × 16 mm [D]
• Install:
Fuel Injection Pump (temporarily)
• gear case.
Align the marks [A] on the injection pump and the timing
• Install:
Fuel Injection Pump Drive Gear and Nut [A]
Camshaft Drive Gear and Bolt
○Face the timing marks [B] on the gears upward.
•Install the idle gear shaft [C] with the arrow [D] facing the
engine top.
•Position the crankshaft key [E] upward (top position).
• Install the idle gear so that the timing marks on the gears
are positioned as shown.
[1] Idle Gear (AA) — (A) Crankshaft Gear
[2] Idle Gear (C) — (CC) or (C) Injection Pump Gear
[3] Idle Gear (BB) — (B) Camshaft Gear
• Install:
Oil Pump Gear [A] and Bolt
Timing Gear Case
•○Temporarily install the flywheel [A] to hold the crankshaft.

Using the flywheel holder [B] angled toward the rear of
the engine, hold the crankshaft.
• Install:
Thrust Plate [A]
• Tighten:
Torque - Idle Gear Bolts [B]: 25 N·m (2.6 kgf·m, 19 ft·lb)
• Position
gine.
the flywheel holder to the forward side of the en-
• Tighten:
Torque - Fuel Injection Pump Gear Nut [C]: 64 N·m (6.5
kgf·m, 47 ft·lb)
Camshaft Gear Bolt [D]: 43 N·m (4.4 kgf·m, 32 ft·lb)
Oil Pump Gear Bolt [E]: 20 N·m (2.0 kgf·m, 14 ft·lb)
• Install:
New Timing Gear Case Cover Gasket
Dowel Pins [F]
• Confirm the small hole in the oil nozzle [A] faces the en-
gagement of the idle gear and camshaft gear.
• Tighten:
Torque - Oil Nozzle: 9.8 ∼ 18 N·m (1.0 ∼ 1.8 kgf·m, 7.2 ∼ 13
ft·lb)
• Install:
Timing Gear Case Cover
Bracket [A]
• Tighten:
Torque - Timing Gear Case Cover Bolts and Nuts: 7.8 N·m
(0.80 kgf·m, 69 in·lb)
Nuts [B]
M6 × 55 mm [C]
M6 × 45 mm [D]
M6 × 30 mm [E]
Timing Gear Case
• Position the flywheel holder [A] back to the rear side of

the engine, as shown.
• Wipe off the excessive oil stuck on the tapered areas of

the pulley and its engaging area with a ragged cloth be-
fore installation.
•Install:
Crankshaft Pulley [A] and Bolt
○Fit the hole [B] in the crankshaft pulley on the pin [C] in
the crankshaft gear.
•Apply thin coat of oil to the threads of tightening bolt. Do
not apply excessive oil to its threads.
•Tighten:
Torque - Crankshaft Pulley Bolt: 98 N·m 10.0 kgf·m, 72 ft·lb)
• Install the parts removed.
• Fuel Injection Pump Timing (see Fuel System chapter)
Adjust:
Timing Gear Case Cover Oil Seal Replacement

• Remove:
Timing Gear Case Cover (see Timing Gear Case Re-
moval)
Oil Seal [A]
• Press
out.
in the oil seal with the manufacturer’s marks facing
Special Tool - Timing Gear Cover Oil Seal Driver [A]: 57001
-1436
Timing Gear Case
Timing Gear Inspection
• Inspect the timing gears using the following sequence.
• and crankshaft
Check the timing gear backlash between the idle gear [A]
gear [B].
• Camshaft Gear
Remove:
Fuel Injection Pump Gear

Oil Pump Gear
○Set the tip of the dial gauge [C] on the idle gear tooth.
○Hold the crankshaft.
○Move the idle gear back and forth noting indicator reading.
Timing Gear Backlash
If the backlash exceeds the service limit, check the idle

gear bearing and shaft for wear.
Idle Gear Inside Diameter [A]
Idle Gear Shaft Outside Diameter [B]

If the idle gear bearing and shaft are within the service
limit, replace the idle gear and recheck the backlash.
If the backlash exceeds the service limit with a new idle
gear, crankshaft gear is worn.
If the crankshaft gear is worn, replace the crankshaft.
• Check the timing gear backlash between the camshaft

gear [A] and idle gear [B].
○Set the tip of the dial gauge [C] on the camshaft gear
tooth.
○Hold the idle gear.
○Move the camshaft gear back and forth noting indicator
reading.
If the backlash exceeds the service limit, replace the
camshaft gear.
• Check the timing gear backlash between the fuel injection

pump gear [A] and idle gear [B].
○Set the tip of the dial gauge [C] on the pump gear tooth.
○Hold the idle gear.
○Move the pump gear back and forth noting indicator read-
ing.
If the backlash exceeds the service limit, replace the fuel
injection pump gear.
Timing Gear Case
• Visually
damage.
inspect the oil pump gear teeth [A] for wear and
If the teeth are damaged or worn, replace the oil pump

gear.
Camshaft
Camshaft Removal
• Remove:
Cylinder Head (see Engine Top End chapter)
Valve Lifters (see Engine Top End chapter)
Timing Gear Case Cover
• Temporarily, install the flywheel to hold the crankshaft.
• Using the flywheel holder [A] angled toward the rear of
the engine, hold the crankshaft.
• Remove:
Camshaft Gear Bolt [A]
Camshaft Gear [B]
○Mark the positions [A] of the camshaft gear [B] and idle
gear [C] so that the camshaft gear can be installed later
in the same position.
○Do not turn the idle gear while the camshaft gear is re-
moved.
• Remove:
Camshaft Retainer Bolts [A]
Camshaft Retainer [B]
Camshaft [C]
○Use care when removing the camshaft to prevent damag-
ing the cam bearings, journals and lobes.
Camshaft Installation
Camshaft [A] (All Cam Parts and Journals)
• Install:
Camshaft
○Take care when installing the camshaft to prevent dam-
aging the cam bearings, journals and lobes.
• Install:
Camshaft Retainer
Camshaft Retainer Bolts
Torque - Camshaft Retainer Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
Camshaft
• Install:
Camshaft Gear [A]
○Fit the groove [B] in the camshaft gear onto the key on
the camshaft.
○Align the marks [C] on the camshaft gear and idle gear
marked when removing.
○If the idle gear is turned, set the timing gears to the original
positions (see Timing Gear Case Installation).
• Move the flywheel holder [A] to the forward side of the

engine to hold the crankshaft.
• Tighten:
Torque - Camshaft Gear Bolt [A]: 43 N·m (4.4 kgf·m, 32 ft·lb)
• Install:
Removed Parts (see appropriate section or chapter)
Camshaft Inspection
• 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.)
Camshaft
• Measure the diameter [A] of the camshaft journals.

If any journals has worn past the service limit, replace the
camshaft.
Camshaft Journal Diameter
Standard
35.959 ~ 35.975 mm(1.4157 ~ 1.4163
Right Side [A]
in.)
35.910 ~ 35.955 mm(1.4138 ~ 1.4155
Center [B]
in.)
35.910 ~ 35.955 mm(1.4138 ~ 1.4155
Left Side [C]
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.)
• Measure the camshaft runout.

If the measurement exceeds the service limit, replace the
camshaft.
Camshaft Runout
Connecting Rod Removal
• Remove:
Engine (see Engine Removal/Installation)
Cylinder Head (see Engine Top End chapter)
Valve Lifters (see Engine Top End chapter)
• Remove the carbon to prevent damaging the piston rings
or piston.
NOTE
○Number the connecting rod/piston assemblies before
removing.
• Remove:
Connecting Rod Cap Nuts [A]
Connecting Rod Cap [B]
• Push the connecting rod end into the cylinder, and pull the
piston and connecting rod out of the cylinder.
• Reassemble the connect rod cap to the connecting rod to
prevent interchanging components.
Connecting Rod Installation
•○Install the connecting rod bearing inserts.
Be 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 to the threads or crankpin
when installing the connecting rod.

Cylinder Bores
Pistons and Piston Rings
Bearing Inserts and Crankpins
• Rotate the crankshaft so that the crankpin is at bottom of
the stroke.
• Insert the piston and connecting rod with the arrow [A] on
the piston facing right side (timing gears side).
○Using 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 50 ∼ 67:
57001-1096

Connecting Rod Bolt Threads
• Install the connecting rod caps with ID mark [A] facing
right side (timing gears side).
• Tighten:
Torque - Connecting Rod Cap Nuts: 36 N·m (3.7 kgf·m, 27
ft·lb)
○After tightening the cap bolts, make sure the crankshaft
rotates freely.
Crankshaft Removal
• 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
• Remove:
Crankshaft Main Bearing Cap Bolts [A]
Crankshaft Main Bearing Caps [B]
Crankshaft [C]
Thrust Washers (#3 Main Bearing)
• Remove the upper main bearing inserts from saddles and
place with the respective bearing caps.
Crankshaft Installation
• Install the upper main bearing inserts in the crankcase.
NOTE
○Upper main bearing inserts have an oil groove [A] and
oil hole [B].
○Be sure the bearing inserts are seated in the saddles,
and the tangs in the bearing inserts are aligned with the
notches in the saddles.
• Install the lower main bearing inserts [A] in the bearing

caps [B].
○Be 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.
Main Bearing Inserts
• Install the thrust washers [A] at #3 main bearing with

grooves [B] facing out.
• Install the crankshaft with the gear facing the right side
(timing gears side).
○Take care not to damage the journals or bearing inserts.
Crankshaft Main Journals
• Install the main bearing caps in their respective positions

with the arrows [A] facing the right side (timing gear side).
• Tighten
[1∼4].
the cap bolts following the tightening sequence
Torque - Crankshaft Main Bearing Cap Bolts: 59 N·m (6.0

kgf·m, 43 ft·lb)
○After tightening the cap bolts, make sure the crankshaft
rotates freely.
• Install:
New Oil Seal Retainer Gasket [A]
Dowel Pins [B]
Oil Seal Retainer
• Tighten:
Torque - Oil Seal Retainer Bolts: 5.4 N·m (0.55 kgf·m, 48
in·lb)
Connecting Rod Big End Side Clearance

•○Measure connecting rod big end side clearance.
Insert 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.)
Connecting Rod Inspection
• Measure the inside diameter [A] of the connecting rod
small end.
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.)
• Measure
end.
the inside diameter [A] of the connecting rod big
○With bearings removed, install the connecting rod cap.

• Tighten:
Torque - Connecting Rod Cap Nuts: 36 N·m (3.7 kgf·m, 27
ft·lb)
If the connecting rod big end out of round exceeds the
service limit, replace the connecting rod.
Connecting Rod Big End
Service Limit
Out of Round: 0.02 mm (0.008 in.)
• Check for a bent or twisted connecting rod.

NOTE
○The thrust faces must be free of any burrs or nicks, or
the connecting rod will not lay flat on a surface plate.
○Put the connecting rod on a surface plate. Any distortion
will be evident by a rocking motion.
If a 0.05 mm thickness gauge can be inserted at the con-
necting rod small end, replace the connecting rod.
Connecting Rod Thrust Faces
Service Limit
Distortion: 0.05 mm (0.0020 in.)
Crankshaft Inspection
• Visually inspect the crankshaft main
crankpins for grooves or signs of scoring.
journals and
If any damage is found, the crankshaft must be re-ground

or replaced.
• 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.)
Out of Round and Taper

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
• The final finishing dimensions should be as shown in the

table.
Finishing Dimensional Specifications
[A] 41.726 ~ 41.750 mm (1.6428 ~ 1.6437 in.)
[B] 36.726 ~ 36.750 mm (1.4459 ~ 1.4468 in.)
[C] R 2.5 mm (0.0984 in.)
[D] R 2.1 mm (0.0827 in.)
• Measure the crankshaft runout at #3 main journal.

If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft #3 Main Journal Runout
• Visually inspect the crankshaft gear teeth [A].

• Inspection). gear inspection procedure (see Timing Gear
Do the timing
If the crankshaft gear teeth are damaged or worn, replace

the crankshaft.
Crankshaft Side Clearance
• Insert a thickness gauge [A] between the thrust washer
and the crank web at the #3 main journal to determine
clearance.
Crankshaft Side Clearance
Standard: 0.02 ~ 0.24 mm (0.0008 ~ 0.0094 in.)
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
• 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] R 2.5 mm (0.0984 in.)
Crankshaft #3 Main Journal Width [A]

Standard: 22.00 ~ 22.07 mm (0.8661 ~ 0.8689 in.)
Connecting Rod Big End Bearing Insert/Crankpin

Wear
• Using plastigage (press gauge) [A], measure the bearing
insert/crankpin clearance.
NOTE
○Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).
○Do not move the connecting rod and crankshaft during
clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin

Clearance
Standard: 0.020 ~ 0.044 mm (0.0008 ~ 0.0017 in.)
Service
0.07 mm (0.0028 in.)
Limit:
If the clearance exceeds the service limit, replace the
bearing insert.
• Repeat the procedure for the other connecting rods.
Crankshaft Main Bearing Insert/Journal Wear
• Using plastigage (press gauge) [A], measure the bearing
insert/journal clearance.
NOTE
○Tighten the crankshaft main bearing cap bolts to the
specified torque (see Crankshaft Installation).
○Do 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.)
If the clearance exceeds the service limit, replace the
bearing insert.
• Repeat the procedure for the other main bearings.
End Plate
End Plate Removal
• Remove:
Torque Converter Case (see Converter System chapter)
• Using the flywheel holder [A], hold the crankshaft.
• Remove:
Coupling Bolts [B]
Flywheel Coupling [C]
• Remove:
Flywheel Mounting Bolts [A]
Flywheel [B]
KAF950-B2 ∼, B6F ∼
•Remove:
Coupling Mounting Bolts [A]
Coupling [B]
Flywheel [C]
• Remove:
End Plate Seal Cover [A] (if necessary)
End Plate Bolts [B]
End Plate [C]
Starter Motor Cables
End Plate
End Plate Installation
• Remove
retainer.
the old sealant, and clean around the oil seal

When the starter motor install, refer to the Starter Motor
Installation in the Electrical System chapter.
• Install:
End Plate
• Tighten:
Torque - End Plate Bolts: 39 N·m (4.0 kgf·m, 29 ft·lb)
• Using the flywheel holder, hold the crankshaft.
• Apply liquid gasket to the end plate seal cover bolts [A].
• Tighten:
Torque - Flywheel Mounting Bolts: 44 N·m (4.5 kgf·m, 33
ft·lb)
KAF950-B1
•Apply a non-permanent locking agent:
Flywheel Coupling Bolts
•Tighten the coupling bolts and flywheel with coupling
mounting bolts following the specified tightening se-
quence.
Torque - Coupling Mounting Bolts: 37 N·m (3.8 kgf·m, 27
ft·lb)
KAF950-B2 ∼, B6F ∼
Torque - Flywheel with Coupling Mounting Bolts: 44 N·m
(4.5 kgf·m, 33 ft·lb)
Oil Seal Retainer
Oil Seal Replacement
• Remove:
Oil Seal Retainer [A] (see Crankshaft Removal)
Oil Seal [B]

Outside of Oil Seal
• 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
○Apply high temperature grease to the oil seal lips.
Piston Removal
• Remove:
Connecting Rod (see Connecting Rod Removal)
Snap Rings [A]
• Remove:
Piston Pin
Special Tool - Piston Pin Puller Assembly [A]: 57001-910
• Carefully spread the ring opening with your thumbs and

then push up on the opposite side of the ring [A] to remove
it.
• Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
Piston Pin
• Align the arrow [A] on the piston and ID mark [B] on the
connecting rod.
• Install:
Piston Pin
Snap Rings
• Install the oil ring coil expander making sure the wire is
completely inserted into the coil expander.
• Install:
Oil Ring Coil Expander
Oil Ring [A]
Second Ring [B]
Top Ring [C]
○The second and top rings must be installed with the “T”
mark [D] facing up.
• Position each piston ring end gap as shown.

Arrow [A]
Top Ring End Gap [B]
Second Ring End Gap [C]
Oil Ring End Gap [D]
Crankcase Removal
• Remove:
Connecting Rods (see Connecting Rod Removal)
Crankshaft (see Crankshaft Removal)
Crankcase [A]
Crankcase Warp
• Clean the crankcase.
• crankcase
Lay a straightedge [A] across the upper surface of the
at several different points, and measure the
warp by inserting a thickness gauge [B] between the
straightedge and the crankcase.
Crankcase Warp
If the warp exceeds the service limit, the crankcase may

be resurfaced to the service limit of the crankcase height
[A].
Crankcase Height
238.70 ~ 239.30 mm (9.3976 ~ 9.4212
Standard:
in.)
If the height is less than the service limit, replace the
crankcase.
Crankcase Wear
Cylinder Bore
•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.
If any of the measurements exceeds the service limit, the
cylinder will have to be bored to oversize and then honed.
[A] 10 mm
[B] 45 mm
[C] 20 mm
Cylinder Inside Diameter
Standard: 72.00 ~ 72.03 mm (2.8346 ~ 2.8358 in.)
72.105 mm (2.8388 in.) or more than
Service Limit: 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.)
Camshaft Bearing
Camshaft Bearing Inside Diameter
If the diameter exceeds the service limit, replace the
camshaft bearing.
Piston Diameter
• Measure the piston diameter [A] at the point shown with
a micrometer.
Piston Diameter
Standard: 71.93 ~ 71.96 mm (2.8319 ~ 2.8331 in.)
NOTE
○If the cylinder has been bored oversize, use the over-
size piston diameter.
Piston/Cylinder Clearance
• Subtract the piston diameter from the cylinder inside di-
ameter to get the piston/cylinder clearance.
Piston/Cylinder Clearance
0.06 ~ 0.08 mm (0.0024 ~ 0.0031
Standard:
in.)
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.
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.
○Oversize pistons require oversize rings.
Oversize Piston and Rings
0.25 mm (0.0098 in.) Oversize
○Before 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.
○Cylinder inside diameter must not vary more than 0.01
mm (0.00039 in.) at any point.
○Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
○In the 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 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 rebored diam-
eter is unknown, it can be roughly determined by measur-
ing the diameter at the base of the cylinder.
Camshaft Bearing Replacement
• Remove:
• camshaft
Using the camshaft bearing remover [A], remove the
bearing.
Special Tool - Camshaft Bearing Remover: 57001-1435
• Install:
New Camshaft Bearing [A]
○Face the notch [B] in the bearing to the outside, and align
the oil holes [C] in the bearing and crankcase.
• Using the camshaft bearing driver [A], install the camshaft

bearing.
Special Tool - Camshaft Bearing Driver: 57001-1434
Camshaft Plug Replacement

• Remove:
• Remove:
Camshaft Plug [A]
○Use a wooden dowel or brass rod to prevent damage to
the camshaft bearing.
• Using the camshaft

camshaft plug.
bearing driver [A], install a new
Special Tool - Camshaft Bearing Driver: 57001-1434
Piston Ring and Ring Groove Wear

• Check
ing.
for uneven groove wear by inspecting the ring seat-
The rings should fit perfectly parallel to the groove sur-

faces. If not, replace the piston and all the piston rings.
• With new piston rings [A] in their grooves, make several
measurements with a thickness gauge [B] 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.)
If the piston ring/groove clearance is greater than the ser-
vice limit, replace the piston.
Piston Ring End Gap
• Clean the carbon from the ends of the rings.
• to locate the
Place the piston ring inside the cylinder, using the piston
ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
• Measure the gap between the ends of the ring with a thick-
ness gauge.
Piston Ring End Gap (Top, Second and Oil Ring)
If the gap is wider than the service limit, the ring is over-
worn and must be replaced.
NOTE
○When 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
•○Measure the piston ring thickness.
Use a 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.)
Oil 2.970 ~ 2.990 mm (0.1169 ~ 0.1177 in.)
Piston and Piston Pin Wear

• Measure the inside diameter of the piston pin bore.
If the inside diameter exceeds the service limit, replace
the piston.
Piston Pin Bore Diameter
• Measure the outside diameter of the piston pin.

If the outside diameter is less than the service limit, re-
place the piston pin.
Piston Pin Diameter
TRANSMISSION 10-1
Transmission
Table of Contents
Exploded View................................... 10-2 2WD/4WD Shift Cable
Specifications .................................... 10-8 Lubrication................................. 10-21
Special Tools and Sealant ................. 10-9 2WD/4WD Shift Cable Inspection 10-21
Transmission Oil................................ 10-10 2WD/4WD Shift Mechanism
Transmission Oil Level Inspection 10-10 Removal ................................... 10-21
Transmission Oil Change............. 10-10 2WD/4WD Shift Mechanism
Transmission Case............................ 10-11 Installation ................................. 10-22
Transmission Case Removal ....... 10-11 2WD/4WD Shift Mechanism
Transmission Case Installation ... 10-11 Inspection.................................. 10-23
Transmission Case Splitting ........ 10-12 Differential Gears and Shift
Transmission Case Assembly...... 10-12 Mechanism ..................................... 10-24
Transmission and Shift Mechanism .. 10-13 Differential Shift Cable
Transmission Shift Cable Adjustment ................................ 10-24
Adjustment ................................ 10-13 Differential Shift Cable
Transmission Shift Cable Lubrication................................. 10-24
Inspection.................................. 10-13 Differential Shift Cable Inspection 10-24 10
Transmission Removal ............... 10-13 Differential Shift Mechanism
Transmission Installation ............. 10-14 Removal .................................... 10-24
Transmission and Shift Differential Shift Mechanism
Mechanism Inspection .............. 10-15 Installation ................................. 10-25
Hi/Low Gears and Shift Mechanism .. 10-16 Differential Shift Mechanism
Hi/Low Shift Cable Adjustment .... 10-16 Inspection.................................. 10-25
Hi/Low Shift Cable Inspection ...... 10-16 Differential Gear Removal............ 10-25
Hi/Low Gear and Shift Mechanism Differential Gear Installation......... 10-26
Removal ................................... 10-16 Differential Gear Inspection ......... 10-26
Hi/Low Gear and Shift Mechanism Bearings and Oil Seal........................ 10-27
Installation ................................ 10-18 Bearing Replacement .................. 10-27
Hi/Low Gear and Shift Mechanism Ball Bearing Inspection ................ 10-27
Inspection ................................. 10-19 Needle Bearing Inspection........... 10-27
2WD/4WD Shift Mechanism .............. 10-20 Oil Seal Inspection ....................... 10-27
2WD/4WD Shift Cable Transmission Sectional Figure .......... 10-28
Adjustment ................................ 10-20
10-2 TRANSMISSION
Exploded View
TRANSMISSION 10-3
Exploded View
1. Clamp (KAF950-B2 ∼, B6F ∼)
2. KAF950B6F ∼
G: Apply grease.
10-4 TRANSMISSION
Exploded View
TRANSMISSION 10-5
Exploded View
Torque Re-
No. Fastener
1 Shift Shaft Stop Bolts 7.8 0.80 69 in·lb
2 Shift Arm Positioning Bolt 37 3.8 27
Differential Gear Housing Bolts (KAF950-B1) 29 3.0 22 L
3
Differential Gear Housing Bolts (KAF950-B2 ∼, B6F ∼) 57 5.8 42 L
4. (KAF950-B1 ∼ B3)
G: Apply grease.
O: Apply engine oil
10-6 TRANSMISSION
Exploded View
TRANSMISSION 10-7
Exploded View
Torque
N·m kgf·m ft·lb
1 Hi/Lo Gear Case Bolts 20 2.0 14
2 Bearing Holder 120 12 87
3 Transmission Oil Drain Plug 15 1.5 11
4 Transmission Case Bolts 8.8 0.90 78 in·lb
5 Neutral Switch 15 1.5 11
6 Transmission Case Mounting Bolts 44 4.5 33
7. KAF950-B2 ∼, B6F ∼ Model.
G: Apply grease.
LG: Apply liquid gasket (Kawasaki Bond: 92104-002).
10-8 TRANSMISSION
Specifications

Transmission Oil
Type API "GL-5" Hypoid gear oil – – –
Viscosity SAE 90: above 5°C (41°F)
SAE 80: below 5°C (41°F)
Between upper and lower
Oil level – – –
level lines
Transmission and Shift Mechanism
Shift Arm Pin Diameter 7.95 ~ 8.00 mm 7.8 mm
(0.3130 ~ 0.3150 in.) (0.3071 in.)
Shifter Block Inside Diameter 8.05 ~ 8.10 mm 8.2 mm
(0.3169 ~ 0.3189 in.) (0.3228 in.)
Shifter Block Outside Diameter 13.95 ~ 14.00 mm 13.8 mm
(0.5492 ~ 0.5512 in.) (0.5433 in.)
Shifter Groove Width 14.0 ~ 14.2 mm 14.3 mm
(0.5512 ~ 0.5591 in.) (0.563 in.)
Hi/Low Gears and Shift Mechanism
(0.5492 ~ 0.5512 in.) (0.5433 in.)
(0.5531 ~ 0.5571 in.) (0.5630 in.)
2WD/4WD Shift Mechanism
(0.5492 ~ 0.5512 in.) (0.5433 in.)
(0.5512 ~ 0.5591 in.) (0.5630 in.)
Differential Gears and Shift Mechanism
Shift Arm Pin Diameter 8.4 ~ 8.6 mm 8.3 mm
(0.3307 ~ 0.3386 in.) (0.3268 in.)
(0.3543 ~ 0.3583 in.) (0.3622 in.)
TRANSMISSION 10-9
Outside Circlip Pliers: Hexagon Wrench, Hex 32:
57001-144 57001-1194
Oil Seal & Bearing Remover: Kawasaki Bond (Liquid Gasket - Silver):
57001-1058 92104-002
Bearing Driver Set:

57001-1129
10-10 TRANSMISSION
Transmission Oil
CAUTION
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
○If the vehicle has just been used wait several minutes
for all the oil to settle down.
• Park the vehicle on level ground, and tilt up the cargo bed.
• insert it intothetheoil filler
Unscrew filler cap [A], wipe its dipstick [B] dry, and
opening but DO NOT SCREW IT IN.
• should be between the upper
Pull out the dipstick and check the oil level. The oil level
(H) and lower (L) level lines
[C].
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device, through the oil filler
opening.
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
○If 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.
Transmission Oil Change
• Refer to the Transmission in the Periodic Maintenance
chapter.
TRANSMISSION 10-11
Transmission Case
Transmission Case Removal
• Remove:
Transmission Oil (drain)
Cargo Bed
Speedometer Cable Rear End
Propeller Shafts (see Final Drive chapter)
Torque Converter Case (see Converter System)
Drive Shafts and Axles (see Final Drive chapter)
Neutral Switch Terminal Lead [A] (disconnect)
Transmission Shift Cable Lower End [B]
Hi/Low Shift Cable Lower End [C]
2WD/4WD Shift Cable Lower End [D]
Differential Shift Cable Lower End [E]
Cable Bracket Mounting Bolts [F] and Collars
Transmission Case Mounting Bolts and Nuts [A]
Transmission Case [B]
Transmission Case Installation

• Tighten:
Torque - Transmission Case Mounting Bolts: 44 N·m (4.5
kgf·m, 33 ft·lb)
• Install:
Speedometer Gear [A]
Washer [B]
O-ring [C]
Bushing [D]
Oil Seal [E]
Thick Holder [F]
Thin Holder [G]
Bolt [H]
• Adjust:
Engine Mounting Position (see Engine Installation)
Transmission Oil
Transmission Shift Cable
Differential Shift Cable
Hi/Low Shift Cable
2WD/4WD Shift Cable
10-12 TRANSMISSION
Transmission Case
Transmission Case Splitting
• Remove:
Cable Bracket
Transmission Case Bolts [A]
Transmission Case (Left) [B]
Transmission Case Assembly

• Check to see that the transmission case knock pins [A]
are in place. If any one of them has been removed, re-
place it with a new one.
• Apply liquid gasket:
Transmission Case Mating Surface
Sealant - Kawasaki Bond (Liquid Gasket -Silver): 92104
-002
• Apply grease:
Oil Seal Lips
• Tighten:
Torque - Transmission Case Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
TRANSMISSION 10-13
Transmission Shift Cable Adjustment
• Loosen the transmission shift cable adjuster nuts [A].
• Position the shift shaft lever [A] so that the opening [B] in
the clamp is aligned with the mark [C] on the transmission
case.
NOTE
○At this time, the transmission gears must be in neutral.
• Slide the adjuster until the transmission shift lever [A] is

in the neutral position [B].
• Tighten the adjuster nuts securely.
Transmission Shift Cable Inspection

• With the cable disconnected at both ends,
should move freely within the cable housing.
the cable
If the cable movement is not free, if the cable is frayed, or

if the housing is kinked, replace the cable.
Transmission Removal
• Remove:
Hi/Low Shift Gears (see Hi/Low Gear and Shift Mecha-
nism Removal)
2WD/4WD Shift Mechanism (see 2WD/4WD Shift Mech-
anism Removal)
Transmission Case (see Transmission Case Splitting)
Drive Shaft [A]
Washers [B]
Drive Shaft Reverse Sprocket [C]
Drive Chains [D]
10-14 TRANSMISSION
• Remove:
Shift Arm Positioning Bolt Assembly [A]
Retaining Pin [B]
• Lift the shift arm [C] and remove the shifter block [D].
• Remove:
Shifter [E]
• Remove:
Drive Shaft (Outer) [A] and Drive Shaft Forward Gear [B]
Shift Arm [C]
Differential Gear Assembly [D]
Driven Shaft Assembly [E]
• Remove:
Circlips [A]
Driven Shaft Reverse Sprocket [B]
Driven Shaft Forward Gear [C]
Driven Shaft [D]
Transmission Installation
• Replace all circlips that were removed with new ones.
NOTE
○Always install 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.
TRANSMISSION 10-15
• Apply transmission oil:

Drive and Driven Shafts
Forward Gears
Reverse Sprockets
Drive Chains
• Apply grease:
Oil Seal Lips
Shift Arm Positioning Ball and Spring
• Install the shifter [A] so that the groove [B] is away from
the forward gear [C].
• Tighten:
Torque - Shift Arm Positioning Bolt: 37 N·m (3.8 kgf·m, 27
ft·lb)
• Check that each gear, sprocket, and shifter spins or slides
freely on its shaft without binding after assembly.
Transmission and Shift Mechanism Inspection
• Visually inspect the forward gears, reverse sprockets,
gear and shaft bushings [A], drive chains, and shifter.
• Replace parts worn beyond the service limit.
Shift Arm Pin Diameter [A]

Standard: 7.95 ~ 8.00 mm (0.3130 ~ 0.3150 in.)
Shifter Block Inside Diameter [B]

Standard: 8.05 ~ 8.10 mm (0.3169 ~ 0.3189 in.)
Shifter Block Outside Diameter [C]

Standard: 13.95 ~ 14.00 mm (0.5492 ~ 0.5512
in.)
Shifter Groove Width [D]

Standard: 14.0 ~ 14.2 mm (0.5512 ~ 0.5591
in.)
10-16 TRANSMISSION
Hi/Low Shift Cable Adjustment
• Put the shift lever [A] in the low position.
• Turn the shift shaft lever [A] clockwise until the lever is
stopped by engaging the shifter with the low gear. In this
case, turn the lever while turning the drive shaft by hand
after setting the lever [B] in "FORWARD" or "REVERSE"
and set the differential shifting lever in "LOCK".
• Screw the cable fully to the joint of the lever [C] and pass
the cable through the cable holder.
• After confirm to fix the punch mark of lever [A] to the mark
(projection) on the gear case, install the slit of lever [C]
to the mark (projection) on the gear in accordance with
figure.
• Tighten the nut [D] of the cable and the bolt [E] of the lever
[C].
• Under the lever [C] in the position turning fully to the Low
side, push the outer cable lightly to the direction of the
arrow on the figure, and tighten the nut [F] (first) and nut
[G] (last) in that position do not move.
Hi/Low Shift Cable Inspection
the cable

Hi/Low Gear and Shift Mechanism Removal

• Remove:
Bevel Gear Case (see Final Drive chapter)
Hi/Low Shift Shaft Lever [A]
2WD/4WD Shift Cable Lower End [B]
TRANSMISSION 10-17
• Remove:
Hi/Low Gear Case Bolts [A]
Hi/Low Gear Case [B]
• Remove:
Washer [A]
High Gear [B]
Shifter [C]
Reduction Gear [D]
• Remove:
Circlip [A]
Washer [B]
Low Gear [C]
Collar
• Remove:
Bolt [A]
Holder [B]
• Remove:
Retaining Pin [A]
Shift Shaft and Arm [B]
10-18 TRANSMISSION
Hi/Low Gear and Shift Mechanism Installation
Hi/Low Gears
Shifter
• Apply grease:
Oil Seal Lips
• Replace the circlip that was removed with a new one.
NOTE
○Always install the circlip [A] so that the opening [B] is
• Install the shifter [A] so that the large dogs [B] face to the
low gear [C].
• Install:
Reduction Gear [A]
High Gear [B]
Washer [C]
Shifter [D]
• Check to see that the hi/low gear case knock pins [E] are
in place on the transmission case. If any one of them has
been removed, replace it with a new one.
• Fit the shift arm pins [A] into the shifter grooves [B].
• Tighten:
Torque - Hi/Low Gear Case Bolts: 20 N·m (2.0 kgf·m, 14
ft·lb)
• Check that each gear and shifter spins or slides freely on
its shaft without binding after assembly.
TRANSMISSION 10-19
Hi/Low Gear and Shift Mechanism Inspection
• Visually inspect the hi/low gears, shifter, and low gear
bushing [A].
Shifter Block Outside Diameter [A]

Standard: 13.95 ~ 14.00 mm (0.5492 ~ 0.5512 in.)
Shifter Groove Width [B]

Standard: 14.05 ~ 14.15 mm (0.5531 ~ 0.5571
in.)
10-20 TRANSMISSION
2WD/4WD Shift Cable Adjustment
• Put the shift lever [A] in the 2WD position.
• Install the 2WD/4WD shift cable [A] to the shift shaft lever
[B] and cable bracket [C].
• Put the shift lever [A] in the 4WD position.
• Turn the shift shaft lever [A] counterclockwise until the

lever is stopped by engaging the shifter dogs with the
dogs on the drive bevel gear shaft.
• Screw in the upper adjuster nut [B] by hand until the inner
cable [C] has no slack while holding the shift lever in the
4WD position.
• Tighten the lower adjuster nut [D] securely.
TRANSMISSION 10-21
NOTE
○If the 2WD/4WD shift cable cannot be adjusted by using
the adjuster at the shift shaft lever, use the adjuster [A]
at the shift lever. Do not forget to tighten the adjuster
nuts [B].
2WD/4WD Shift Cable Lubrication

Whenever the shift cable is removed, lubricate the cable
as follows.
• Refer to the 2WD/4WD Shift Cable Lubrication in the Pe-
riodic Maintenance chapter.
2WD/4WD Shift Cable Inspection
the cable

2WD/4WD Shift Mechanism Removal

• Remove:
Hi/Low Gear Case (see Hi/Low Gear and Shift Mecha-
nism Removal)
Shift Shaft Stop Bolt [A]
• Remove:
Shift Shaft Lever Mounting Nut [A]
Shift Shaft Lever [B]
Spring [C]
Shift Shaft and Arm [D]
10-22 TRANSMISSION
• Remove:
Shifter [A]
Circlip [B]
Speedometer Gear [C]
Collar
2WD/4WD Shift Mechanism Installation

• Apply grease:
Shift Shaft O-ring
• Install
shown.
the shift shaft lever [A] to the shift shaft arm [B] as
Torque - Shift Shaft Stop Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Install:
Collar [A]
• [C] faces
Install the speedometer gear [B] so that the stepped side
in.
• Replace the circlip that was removed with a new one.

NOTE
○Always install the circlip [A] so that the opening [B] is
TRANSMISSION 10-23
2WD/4WD Shift Mechanism Inspection
• Visually inspect:
Dogs on Shifter [A]
Shifter Groove [B]
Dogs on Drive Bevel Gear Shaft [C]
Shifter Block [D]
If they are damaged or worn excessively, replace them.
Shifter Block Outside Diameter
13.95 ~ 14.00 mm (0.5492 ~ 0.5512
Standard:
in.)
Shifter Groove Width

Standard: 14.0 ~ 14.2 mm (0.5512 ~ 0.5591 in.)
10-24 TRANSMISSION
Differential Shift Cable Adjustment
• Put the shift lever [A] in the LOCK position.
• Turn the shift shaft lever [A] clockwise until the lever is
stopped by engaging the shifter dogs with the dogs on
the differential gear.
• Screw in the upper adjuster nut [B] by hand until the inner
cable [C] has no slack while holding the shift lever in the
LOCK position.
• Tighten the lower adjuster nut [D] securely.
Differential Shift Cable Lubrication

Whenever the shift cable is removed, lubricate the cable
as follows.
• Refer to the Differential Shift Cable Lubrication in the Pe-
riodic Maintenance chapter.
Differential Shift Cable Inspection
the cable

Differential Shift Mechanism Removal

• Remove:
Drive Shafts and Axles
Shift Shaft Stop Bolt [A]
Shift Shaft Lever Mounting Nut [B]
Shift Shaft Lever [C]
Spring [D]
Shift Shaft and Arm [E]
TRANSMISSION 10-25
Differential Shift Mechanism Installation
• Apply grease:
Shift Shaft O-ring
• Install the shift shaft lever [A] to the shift arm [B] as shown.
Torque - Shift Shaft Stop Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Differential Shift Mechanism Inspection

Splines on Drive Shaft [A]
Splines on Shifter [B]
Dogs on Shifter
Shifter Groove
Shift Arm Pin [A]
Dogs on Differential Gear Housing [B]
If they are damaged or worn excessively, replace them.

Shift Arm Pin Diameter [A]
Standard: 8.4 ~ 8.6 mm (0.3307 ~ 0.3386 in.)
Shifter Groove Width [B]

Standard: 9.0 ~ 9.1 mm (0.3543 ~ 0.3583 in.)
Differential Gear Removal

• Remove:
Transmission Case (split)
Differential Gear Assembly [A]
10-26 TRANSMISSION
• Remove:
Differential Gear Housing Bolts [A]
Final Gear [B]
• Remove:
Housing Cover [A]
Knock Pin [B]
Side Gear [C]
Spacer [D]
• Remove:
Knock Pins [A]
Retaining Pin [B]
Pinion Gear Shaft [C]
Pinion Gears [D]
Spacers
Side Gear [E]
Spacer
Differential Gear Installation

Side Gears
Pinion Gears
Differential Gear Housing Bolts
• Tighten:
Torque - Differential Gear Housing Bolts: 29 N·m (3.0
kgf·m, 22 ft·lb) (KAF950B1)
Differential Gear Housing Bolts: 57 N·m (5.8
kgf·m, 42 ft·lb) (KAF950B2 ∼, B6F ∼)
Differential Gear Inspection

• Visually inspect the differential gears [A].
Replace the gears as a set if either gear is damaged.
TRANSMISSION 10-27
Bearings and Oil Seal
Bearing Replacement
• Using a press, a puller, the oil seal & bearing remover, or
the bearing driver set, remove the bearings.
Special Tools - Oil Seal & Bearing Remover: 57001-1058
Bearing Driver Set: 57001-1129
• 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
• Apply oil:
Drive Bevel Gear Shaft Bearing Holder
• Tighten:
Torque - Bearing Holder: 120 N·m (12 kgf·m, 87 ft·lb)
• Using a press and the bearing driver set, install the new
bearings and/or new oil seals.
Ball Bearing Inspection

• Examine the bearing seal [A] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
• Turn [B] each bearing back and forth while checking for
roughness or binding.
If roughness or binding is found, replace the bearing.
Needle Bearing Inspection

•○Check the needle bearing.
The 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.
If there is any doubt as to the condition of a needle bear-
ing, replace it.
Oil Seal Inspection
• 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.
10-28 TRANSMISSION
Transmission Sectional Figure
TRANSMISSION 10-29
Transmission Sectional Figure
WHEELS/TIRES 11-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Wheel Alignment .................................................................................................................... 11-5
Toe-in Adjustment ............................................................................................................. 11-5
Wheels (Rims) ........................................................................................................................ 11-6
Wheel Removal................................................................................................................. 11-6
Wheel Installation.............................................................................................................. 11-6
Wheel (Rim) Inspection..................................................................................................... 11-6
Wheel (Rim) Replacement................................................................................................ 11-6
Tires........................................................................................................................................ 11-8
Tire Removal .................................................................................................................... 11-8
Tire Installation ................................................................................................................. 11-8
Tire Wear Inspection ......................................................................................................... 11-9
11
11-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 11-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Tie-rod End Lockunuts 49 5.0 36
2 Wheel Nuts 140 14 100
R: Replacement parts.
W: Apply a soap and water solution, or water.
11-4 WHEELS/TIRES
Specifications

Wheel Alignment
Caster 7.5° (non-adjustable) – – –
Camber 0.8° (non-adjustable) – – –
Toe-in 0 ∼ 20 mm (0 ~ 0.79 in.) – – –
Tires/Rims
Standard Tire:
Front and Rear 23 × 11.00-10 – – –
Dunlop KT869 Tubeless
Tire Air Pressure (when cold):
Front 69 kPa (0.7 kgf/cm², 10 psi) – – –
Rear 167 kPa (1.7 kgf/cm², 24 psi) – – –
Maximum Tire Air Pressure 250 kPa (2.5 kgf/cm², 36 psi) – – –
(To seat beads, when cold)
Tire Tread Depth 13.2 mm (0.520 in.) 3 mm (0.12 in.)
Rim Size:
Front and Rear 10 × 8.50 – – –
WHEELS/TIRES 11-5
Wheel Alignment
Toe-in is the amount that the front wheels are closer
together 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. 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
• Lift the front wheels off the ground.
• tires. a heavy coat of chalk near the center of the front
Apply
• Using a needle nose scriber, make a thin mark near the

center of the chalk coating while turning the wheel.
• Set the wheels so that the marks on the tires are at the
front side and at the level of the axle height.
• Ground the front wheels.
• At the level of thewheel
Set the steering straight ahead.
• tween the scribed lines height,
axle measure the distance be-
with a measure.
• Move the vehicle rearward until the marks on the front

tires are at the rear side and at the same level as the axle.
• Measure the distance [A] between the scribed lines.
• 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.)
If the toe-in is not the specified value, perform the follow-
ing procedure.
• Check the length [A] of the tie-rod distance between the

rod groove [B] and the locknut [C].
Tie-rod Length (distance between groove and locknut)
If the length is out of the specified, adjust the tie-rod
length.
• Loosen the locknut and turn the adjusting rod [D] to
achieve the specified value.
Front [E]
NOTE
○The toe-in will be near the specified range, if the tie-rod
length is the specified value on the left and right.
• Tighten:
Torque - Tie-rod End Locknuts: 49 N·m (5.0 kgf·m, 36 ft·lb)
• Check the toe-in again.
• Test drive the vehicle.
11-6 WHEELS/TIRES
Wheels (Rims)
Wheel Removal
• Loosen the wheel nuts [A] (Do not remove).
• Remove:
Lift the wheel(s) off the ground.
• Wheel Nuts
Wheel(s)
Wheel Installation
• Position the wheel so that the valve stem [A] is toward the
outside of the vehicle.
• Tighten:
Torque - Wheel Nuts: 140 N·m (14 kgf·m, 100 ft·lb)
○Tighten the wheel nuts in a criss-cross pattern.
Wheel (Rim) Inspection

• Examine both sides of the rim for dents [A].
If the rim is dented, replace it.
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

• Remove the wheel (see Wheel Removal).
• Remove the tire from the rim.
• Remove the valve stem and discard it.
CAUTION
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
Plastic Cap [A] Valve Stem [D]

Valve Core [B] Valve Seat [E]
Stem Seal [C] Valve Opened [F]
WHEELS/TIRES 11-7
Wheels (Rims)
•○Install a new air valve in the new rim.

Remove the valve cap, lubricate the stem with a soap and
water solution, and pull the stem [A] through the rim from
the inside out until it snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to lu-
bricate the stem because they will deteriorate the
rubber.
• Mount the tire on the new rim.

• Install the wheel (see Wheel Installation).
11-8 WHEELS/TIRES
Tires
Tire Removal
• 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.
CAUTION
Do not lubricate the tire beads and rim flanges with
engine oil or petroleum distillates because they will
deteriorate the tire.
• Remove the tire from the rim using a suitable commer-

cially available tire changer.
NOTE
○The tires cannot be removed with hand tools because
they fit the rims tightly.
Tire Installation
• Inspect the rim.
• Check the tire for wear and damage.
• Replace the air valve with a new one.
CAUTION
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
• Lubricate the tire beads and rim flanges with a soap and
water solution, or water.
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.
• Install the tire on the rim using a suitable commercially

available tire changer.
• Lubricate
rim.
the tire beads again and center the tire on the
• Support the wheel rim [A] on a suitable stand [B] to pre-

vent the tire from slipping off.
• 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 kgf/cm², 36 psi)
WARNING
Do not inflate the tire to more than the maximum tire
air pressure. Overinflation can explode the tire with
possibility of injury and loss of life.
WHEELS/TIRES 11-9
Tires
• Check to see that the bead lines [A] on both sides of the
tire are parallel with the rim flanges [B].
If the bead lines and the rim flanges are not parallel, de-
flate the tire, lubricate the sealing surfaces again, and re-
inflate the tire.
•After the beads are properly seated, check for air leaks.
○Apply a soap and water solution around the tire bead and
check for bubbles.
• Check the tire pressure using an air pressure gauge [A].

NOTE
○Kawasaki provides the air pressure gauge (P/N 52005
-1031) as the owner’s tool.
Tire Air Pressure (when cold)

Front: 69 kPa (0.7 kgf/cm², 10 psi)
Rear: 167 kPa (1.7 kgf/cm², 24 psi)
• Install the wheel (see Wheel Installation).

• Wipe off the soap and water solution, or water on the tire,
and dry the tire before operation.
WARNING
Do not operate the vehicle with the water and soap,
or water still around the tire beads. They will cause
tire separation, and a hazardous condition may re-
sult.
WARNING
Inflate both front tires to the same pressure and
both rear tires to the same pressure. Operating with
unequally or improperly pressurized tires can ad-
versely affect steering or handling.
Tire Wear Inspection

• Refer to the Wheels/Tires in the Periodic Maintenance
chapter.
FINAL DRIVE 12-1
Final Drive
Table of Contents
Exploded View................................... 12-2 Bevel Gear Case ............................... 12-24
Specifications .................................... 12-6 Bevel Gear Case Removal .......... 12-24
Special Tools ..................................... 12-7 Bevel Gear Case Installation ....... 12-24
Front Final Gear Case ....................... 12-9 Bevel Gear Case Disassembly .... 12-24
Front Final Gear Case Oil Level Bevel Gear Case Assembly ......... 12-25
Inspection ................................. 12-9 Drive Bevel Gear Removal .......... 12-26
Front Final Gear Case Oil Drive Bevel Gear Installation ....... 12-26
Change...................................... 12-10 Bevel Gear Adjustment ............... 12-26
Front Final Gear Case Removal .. 12-10 Bevel Gear Inspection.................. 12-30
Front Final Gear Case Installation 12-11 Ball Bearing/Oil Seal Inspection... 12-31
Front Final Gear Case Damper Inspection....................... 12-31
Disassembly.............................. 12-11 Propeller Shafts ................................. 12-32
Front Final Gear Case Assembly. 12-12 Propeller Shaft Removal .............. 12-32
Differential Unit and Ring Gear Propeller Shaft Installation ........... 12-33
Disassembly.............................. 12-13 Propeller Shaft Inspection............ 12-33
Differential Unit and Ring Gear Drive Shaft and Axles ........................ 12-34
Assembly................................... 12-13 Front Axle Removal ..................... 12-34
LSD Clutch Torque Inspection ..... 12-14 Front Axle Installation .................. 12-34
LSD Clutch Plate Inspection ........ 12-14 Rear Drive Shaft and Axle
Pinion Gear Unit Disassembly ..... 12-15 Removal .................................... 12-34 12
Pinion Gear Unit Assembly .......... 12-15 Rear Drive Shaft and Axle
Front Final Bevel Gear Installation ................................. 12-35
Adjustment ................................ 12-16 Drive Shaft and Axle Inspection... 12-35
Bevel Gear Inspection.................. 12-23 Dust Boot Inspection.................... 12-36
Differential Gear Inspection ......... 12-23 Front Axle Joint Boot
Tapered Roller Bearing Replacement ............................. 12-36
Inspection.................................. 12-23 Ball Bearing Inspection ................ 12-40
Ball Bearing Inspection ................ 12-23 Grease Seal Inspection................ 12-41
Oil Seal Inspection ....................... 12-23
12-2 FINAL DRIVE
Exploded View
FINAL DRIVE 12-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Oil Filler Cap 29 3.0 22
2 Oil Drain Plug 20 2.0 14
3 Gear Case Bracket Bolts 44 4.5 33
4 Gear Case Mounting Nuts 44 4.5 33
5 Ring Gear Cover Bolts (10 mm) 47 4.8 35
6 Ring Gear Cover Bolts (8 mm) 25 2.5 18
7 Pinion Gear Bearing Housing Nuts 25 2.5 18
8 Differential Case Torx Bolts 32 3.3 24 L
9 Ring Gear Bolts 49 5.0 36
10 Pinion Gear Slotted Nut 120 12 87 MO
11 Drive Shaft Cap Bolts 8.8 0.90 78 in·lb
G: Apply grease.
MO: Apply molybdenum disulfide oil.
12-4 FINAL DRIVE
Exploded View
FINAL DRIVE 12-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Bevel Gear Case Bolt 22 2.2 16
2 Driven Gear Shaft Nut 110 11 80 L
3 Bearing Holder 120 12 87 L
4 Housing Locknut 120 12 87 L
5 Bevel Gear Case Holder Nuts 25 2.5 18
6 Drive Gear Nut 120 12 87 MO
7. Front propeller shaft
8. Rear propeller shaft
9. Transmission case
10. Left rear brake panel
11. Rear axle bracket
G: Apply grease.
HG: Apply grease to the surface (Amco Rykon Premium Grease No. 2 EP Green)
MO: Apply molybdenum disulfide oil.
(The weight ratio of the mixture between engine oil and disulfide grease is 10 : 1)
12-6 FINAL DRIVE
Specifications

Front Final Gear case
Gear Case Oil:
Type API "GL-5 or GL-6" hypoid gear oil for LSD – – –
(Limited Slip Differential gears)
Viscosity SAE 90, or SAE 140 – – –
Oil Level Filler opening level – – –
LSD Clutch Torque 7.8 ∼ 13 N·m – – –
(0.8 ∼ 1.3 kgf·m, 69 ∼ 110 in·lb)
Outside Friction Plate Thickness 2.3 ∼ 2.4 mm (0.091 ∼ 0.094 in.) 2.1 mm (0.083 in.)
Inside Friction Plate Thickness 2.7 ∼ 2.8 mm (0.106 ∼ 0.110 in.) 2.4 mm (0.094 in.)
Pinion Gear Bearing Preload 1.5 ∼ 3.0 N (0.15 ∼ 0.30 kgf) – – –
Pinion Gear Bearing Preload 0.3 ∼ 0.6 N·m – – –
Torque (0.03 ∼ 0.06 kgf·m, 2.6 ∼ 5.2 in·lb)
Bevel Gear Backlash 0.09 ∼ 0.20 mm (0.0035 ∼ 0.0079 in.) – – –
(at ring gear tooth)
Bevel Gear Case
Bevel Gear Backlash 0.08 ∼ 0.18 mm (0.0031 ∼ 0.0071 in.) – – –
(at housing locknut groove)
FINAL DRIVE 12-7
Special Tools
Bearing Puller: Socket Wrench:
57001-135 57001-1283
Outside Circlip Pliers: Pinion Gear Holder:

57001-144 57001-1285
Oil Seal & Bearing Remover: Hexagon Wrench, Hex 40:

57001-1058 57001-1324
Bearing Driver Set: Socket Wrench:

57001-1129 57001-1363
Pinion Gear Holder: Transmission Gear Holder:

57001-1281 57001-1364
12-8 FINAL DRIVE
Special Tools
Transmission Gear Holder:
57001-1676
FINAL DRIVE 12-9
Front Final Gear Case
Front Final Gear Case Oil Level Inspection
• Park the vehicle so that it is level, both side-to-side and
front-to-rear.
• Remove the front guard [A] (see Frame chapter).
• Remove:
Front Final Gear Case Skid Plate Bolts [A]
Front Final Gear Case Skid Plate [B]
(Front View)
(Rear View)
• Remove:
Filler Cap [A]
CAUTION
Be careful not to allow any dirt or foreign materials
to enter the gear case.
• Check the oil level. The oil level should come to the bot-
tom [B] of the filler opening [A].
12-10 FINAL DRIVE
If it is insufficient, first check the front final gear case for
oil leakage, remedy it if necessary, and add oil through
the filler opening [A]. Use the same type and brand of oil
that is already in the final gear case.
• Be sure the O-ring [B] is in place, and tighten the filler cap.
Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb)
Front Final Gear Case Oil Change

• Refer to the Final Drive section in the Periodic Mainte-
nance chapter.
Front Final Gear Case Removal
• Remove the following (see Frame chapter).
Front Guard [A]
Lower Guards [B]
Front Cover [C]
• Remove the front radiator (see Cooling System chapter).
• Remove:
Front Final Gear Case Oil (drain, see Front Final Gear
Case Oil Change in the Periodic Maintenance chapter)
Front Propeller Shaft (see Propeller Shaft Removal)
Front Axles (see Front Axle Removal)
Front Final Gear Case Mounting Bolts [A] and Nuts [B]
Collar [C]
Water Pipe [D] (move it leftwards)
Front [E]
○To move the water pipe leftwards and remove the top
mounting nut, loosen the water pipe bracket bolt [A] and
screw [B] on the floor of the driver’s cage.
Front [C]
FINAL DRIVE 12-11
Front Final Gear Case Mounting Bolt [A]
Front [B]
• Remove (front view):

Front Final Gear Case Bracket Bolts [A]
Front Final Gear Case Bracket [B]
• Remove the front final gear case [A] with mounting bolt
[B] from the front.
• Pull
moval.
off the vent hose [C] from the case to complete re-
Front Final Gear Case Installation

• Route the gear case vent hose correctly according to the
General Information chapter.
• Tighten:
Torque - Gear Case Bracket Bolts: 44 N·m (4.5 kgf·m, 33
ft·lb)
Gear Case Mounting Nuts: 44 N·m (4.5 kgf·m, 33
ft·lb)
• Adjust the front final gear case oil (see Front Final Gear
Case Oil Level Inspection in this chapter).
Front Final Gear Case Disassembly
• Remove:
Front Final Gear Case (see Front Final Gear Case Re-
moval)
Bearing Housing Nuts [A]
Pinion Gear Unit [B]
12-12 FINAL DRIVE
• Remove:
Spacers [A] (both sides)
• bolts [B].the ring gear cover bolts, starting with the smaller
Remove
Larger Bolts [C]

Ring Gear Cover [D]
• Remove:
Ring Gear [A]
Differential Unit [B]
Front Final Gear Case Assembly

• 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.
• Check that the ring gear is installed on the correct side of
the differential caps [A] as shown.
• Install the following parts in the order listed.
Differential Unit and Ring Gear
Ring Gear Shim [B]
Ring Gear Cover
Pinion Gear Unit
• Install the pinion gear unit with the ring gear side of the
case facing down.
•○Align the air vent passage [A] with the hose nipple [B].
First tighten the 10 mm bolts, then tighten the 8 mm bolts.
Torque - Ring Gear Cover Bolts (10 mm): 47 N·m (4.8 kgf·m,
35 ft·lb)
Ring Gear Cover Bolts(8 mm): 25 N·m (2.5 kgf·m,
18 ft·lb)
Pinion Gear Bearing Housing Nuts: 25 N·m (2.5
kgf·m, 18 ft·lb)
• Adjust:
Front Final Gear Backlash (see Front Final Bevel Gear
Adjustment)
Front Final Gear Tooth-Contact (see Front Final Bevel
Gear Adjustment)
FINAL DRIVE 12-13
Differential Unit and Ring Gear Disassembly
• Remove the differential unit and ring gear (see Front Final
Gear Case Disassembly).
CAUTION
Do not interchange the right and left side parts in
the differential unit.
• Remove
unit.
the following parts to disassemble the differential
Ring Gear Bolts [A]

Ring Gear [B]
Differential Caps [C]
Mark here to assemble later [D]
○ clutch plates, springs, spring shims, and side gears
The
come out.
Differential Unit and Ring Gear Assembly
CAUTION
Be sure to install the right and left side parts of the
unit in the original position.
• Inspect the clutch plates (see Clutch Plate Inspection) and

the other differential unit parts. Replace any damaged
parts.
• Measure and record the thickness of the original clutch
spring shim(s).
• Apply specified gear oil to the differential unit parts.
• Note direction and position of the friction plate and the
clutch spring.
Clutch Spring Shim(s) [A] Steel Plate [D]
Clutch Spring [B] Inside Friction Plate [E]
Outside Friction Plate [C]
• Be sure to assemble the differential unit and inspect the

clutch torque (see LSD Clutch Torque Inspection).
Tapped Holes [A] for Ring Gear
Line Mark [B] for assembly
• Install the front axles [C] to center the steel plates.
Differential Case Torx Bolts [D]
• Tighten:
Torque - Differential Case Torx Bolts: 32 N·m (3.3 kgf·m, 24
ft·lb)
Ring Gear Bolts: 49 N·m (5.0 kgf·m, 36 ft·lb)
12-14 FINAL DRIVE
LSD Clutch Torque Inspection
• After assembling the differential unit and ring gear, check
the LSD clutch torque.
• Remove the ring gear from the differential unit [A].
• Hold one offront
Insert both axles [B] in the unit.
• Install the hub nut on axles
the front with a vise.
• Measure the clutch torque using axle.
the other
• the wrench evenly. a torque wrench [C]. Turn
○The clutch torque is the mean torque reading during about

a quarter turn of the wrench.
LSD Clutch Torque
7.8 ∼ 13 N·m (0.8 ∼ 1.3 kgf·m, 69 ∼ 110
Standard:
in·lb)
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(s).
•Also, check the clutch plates and replace them as neces-
sary (see Clutch Plate Inspection).
•To increase clutch torque, increase the thickness of the
shim(s).
○Change the thickness a little at a time.
•Recheck the clutch torque and readjust as necessary.
Thickness Part Number
0.8 mm (0.031 in.) 92180-1121
1.0 mm (0.039 in.) 92180-1122
1.2 mm (0.047 in.) 92180-1123
1.4 mm (0.055 in.) 92180-1124
1.6 mm (0.063 in.) 92180-1125
LSD Clutch Plate Inspection

• Visually inspect the friction plates and steel plates to see
if they show any signs of seizure, overheating, or uneven
wear.
If any plates show signs of damage, or if the friction plates
have worn past the service limit, replace the friction plates
and steel plates as a set.
Outside Friction Plate [A]
Inside Friction Plate [B]
Outside Friction Plate Thickness
Standard: 2.3 ∼ 2.4 mm (0.091 ~ 0.94 in.)
Inside Friction Plate Thickness

Standard: 2.7 ∼ 2.8 mm (0.106 ~ 0.110 in.)
FINAL DRIVE 12-15
Pinion Gear Unit Disassembly
• Remove the pinion gear unit (see Front Final Gear Case
Disassembly).
• Pry open the toothed washer tab [A] on the pinion gear
slotted nut [B].
• Unscrew the pinion gear slotted nut.

Special Tools - Pinion Gear Holder: 57001-1281 [A]
Socket Wrench: 57001-1283 [B]
• Remove the slotted nut, flat washer, and toothed washer.
• Remove the tapered
Pull the pinion gear out of the bearing housing.
• sary. roller bearing inner race as neces-
Special Tool - Bearing Puller: 57001-135
Pinion Gear Unit Assembly

• The 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.
•Visually inspect the tapered roller bearings for abrasion,
color change, or other damage.
If there is any doubt as to the condition of a bearing, re-
place the bearing housing and the bearings as a set.
•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).
○When the pinion gear slotted nut is loosened, even if the
purpose is not to replace the parts, check and adjust the
bearing preload.
•Fit the toothed washer claw [A] into the shaft.
•Apply molybdenum dislufide oil to the threads and seating
surface of the pinion gear slotted nut, and tighten it.
Torque - Pinion Gear Slotted Nut : 120 N·m (12 kgf·m, 87
ft·lb)
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.
• Bend the tab over the nut.
12-16 FINAL DRIVE
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.
• 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.
• The amount of backlash is influenced by the ring gear
position more than by the pinion gear position.
• Tooth contact location is influenced by pinion gear posi-
tion more than by ring gear position.
FINAL DRIVE 12-17
Bearing Preload Adjustment:
•Check and adjust the bearing preload in the following
cases.
○When 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
○When the pinion gear slotted nut [B] is loosened; even if
the nut is not removed.
•Install the pinion gear bearing housing and tighten the
pinion gear slotted nut to the specified torque (see Pinion
Gear Unit Disassembly/Assembly).
•Do not install the oil seal and O-rings, and do not lock the
washer until the correct bearing preload is obtained.
CAUTION
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.
• Apply specified gear oil to the bearings, and turn the gears
more than 5 turns to allow the bearings to seat.
• Measure the bearing preload. Bearing preload is the force
or torque which is needed to start the gear shaft turning.
NOTE
○Preload can be measured either with a spring scale or
a beam-type torque wrench. When measured with a
spring scale, the preload is designated by force (N, kgf),
and when measured with a torque wrench, it is desig-
nated by torque (N·m, kgf·m, in·lb).
12-18 FINAL DRIVE
Front Final Gear Case (Backlash-Related Parts)
1. Ring Gear Cover

2. Front Final Gear Case
3. Ring Gear
4. Ring Gear Shims for Backlash Adjustment
5. Left Differential Cap
6. Ball Bearing
7. Collar for Preload Adjustment (affects preload only)
8. Shims for Preload Adjustment (affects preload only)
9. Pinion Gear Shims for Tooth Contact Adjustment
10. Right Differential Cap
11. Pinion Gear
12. Tapered Roller Bearing
13. Pinion Gear Bearing Housing
14. Tapered Roller Bearing (affects preload only)
15. Oil Seal Collar (affects preload only)
16. Pinion Gear Slotted Nut (affects preload only)
F: Front
FINAL DRIVE 12-19
Ring Gear Shims [4] for Backlash Adjustment Shims [8] for Preload Adjustment
Thickness Part Number Thickness Part Number
0.1 mm (0.0039 in.) 92025-1850 1.70 mm (0.067 in.) 92025-1072
0.15 mm (0.0059 in.) 92025-1851 1.72 mm (0.068 in.) 92025-1073
0.5 mm (0.0197 in.) 92025-1856 1.74 mm (0.0685 in.) 92025-1074
0.8 mm (0.031 in.) 92025-1857 1.76 mm (primary, 0.0693 in.) 92025-1075
1.0 mm (primary, 0.039 in.) 92025-1849 1.78 mm (0.070 in.) 92025-1076
Collars [7] for Preload Adjustment 1.80 mm (0.071 in.) 92025-1077
Thickness Part Number Pinion Gear Shims [9] for Tooth Contact Adjustment
10.2 mm (0.402 in.) 92027-1401 Thickness Part Number
10.3 mm (0.406 in.) 92027-1402 0.1 mm (0.0039 in.) 92025-1919
10.4 mm (0.409 in.) 92027-1403 0.15 mm (0.0059 in.) 92025-1920
10.5 mm (0.413 in.) 92027-1404 0.5 mm (0.0197 in.) 92025-1921
10.6 mm (0.417 in.) 92027-1405 0.8 mm (0.031 in.) 92025-1922
10.7 mm (primary, 0.421 in.) 92027-1406 1.0 mm (primary, 0.039 in.) 92025-1923
10.8 mm (0.425 in.) 92027-1407 1.2 mm (0.047 in.) 92025-1924
10.9 mm (0.429 in.) 92027-1408
11.0 mm (0.433 in.) 92027-1409
11.1 mm (0.437 in.) 92027-1410
11.2 mm (0.441 in.) 92027-1411
If the preload is out of the specified range, replace the

collar and/or shim(s).
○To increase preload, decrease the size of the shim(s)
or collar. To decrease preload, increase the size of the
shim(s) or collar.
•Recheck the bearing preload, and readjust as necessary.
• Measure the bearing preload using a spring scale.

Using Spring Scale
Pinion Gear Bearing
1.5 ∼ 3.0 N (0.15 ∼ 0.30 kgf)
Preload:
○Hook the spring scale [A] on the handle at a point 200
mm [B] apart from the center of the gear shaft. Hold the
bearing housing in a vise so that the gear shaft is vertical.
○Apply force to the handle horizontally and at a right angle
to it.
Special Tool - Pinion Gear Holder: 57001-1281 [C]
12-20 FINAL DRIVE
• 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·lb)
Special Tool - Pinion Gear Holder: 57001-1281 [B]
Backlash Adjustment
•Check and adjust the gear backlash when any of the
backlash-related parts are replaced with new ones.
•Clean any dirt and oil off the bevel gear teeth.
•Assemble the front final gear case (see Front Final Gear
Case Assembly). Do not install the O-rings during adjust-
ment.
○Check 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.
•Set up a dial gauge against a ring gear tooth to check gear
backlash shown.
•To measure the backlash, move the left front axle (ring
gear side) back and forth while holding the pinion gear
steady. The difference between the highest and the low-
est gauge reading is the amount of backlash.
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).
•Recheck the backlash, and readjust as necessary.
• Move the front axle back and forth [A].

Dial Gauge [C]
Bevel Gear Backlash
Standard: 0.09 ∼ 0.20 mm
(0.035 ∼ 0.0079 in.) (at ring gear tooth)
FINAL DRIVE 12-21
Tooth Contact Adjustment
• Clean any dirt and oil off the bevel gear teeth.
• Apply checking compound to 4 or 5 teeth on the pinion
gear.
NOTE
○Apply 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.
○The checking compound must be smooth and firm, with
the consistency of tooth paste.
○Special 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.
• Assemble the front final gear case (see Front Final Gear
Case Assembly). Do not install the O-rings during adjust-
ment.
•Turn the pinion gear shaft for one revolution in the drive
and reverse (coast) direction, while creating a drag on the
ring gear.
○Use the pinion gear holder [A] and the left front axle.
Special Tool - Pinion Gear Holder: 57001-1281
• Remove the ring gear and pinion gear unit to 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. 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.
If the tooth contact pattern is incorrect, replace the pinion
gear shim(s), following the examples shown.
• 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
○If 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 checking the
tooth contact pattern.
12-22 FINAL DRIVE
Correct Tooth Contact Pattern: No adjustment is required.
Heel [A] Bottom [B] Top [C] Toe [D] Ring Gear [E] Pinion Gear [F]
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 above. Repeat in 0.05 mm (0.002 in.) steps if necessary.
Incorrect Tooth Contact Patterns (Example 2)
○Increase the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern
shown above. Repeat in 0.05 mm (0.002 in.) steps if necessary.
FINAL DRIVE 12-23
Bevel Gear Inspection
• 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

• Visually check the differential gears [A] for scoring, chip-
ping, or other damage.
• Also, inspect the differential pinion gear shaft [B] and gear
housing [C] where the differential gears rub.
If they are scored, discolored, or otherwise damaged, re-
place them as a set.
Tapered Roller Bearing Inspection

• Visually inspect the bearings
change, or other damage.
[A] for abrasion, color
If there is any doubt as to the condition of a bearing, re-

place it.

• 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.
• Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
Oil Seal Inspection

• Visually inspect the oil seal.
otherwise damaged.
12-24 FINAL DRIVE
Bevel Gear Case
Bevel Gear Case Removal
• Remove:
Transmission Oil (drain, see Transmission Oil Change in
the Periodic Maintenance chapter)
Cargo Bed (see Frame chapter)
Propeller Shafts (see Propeller Shaft Removal)
Bevel Gear Case Bolts [A]
Bevel Gear Case [B]
Bevel Gear Case Installation

• Check and adjust the bevel gear backlash and tooth con-
tact when any of the backlash-related parts are replaced
(see Bevel Gear Adjustment).
• Check to see that the bevel gear case knock pin [A] is in
place.
• Tighten:
Torque - Bevel Gear Case Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)
Bevel Gear Case Disassembly

• Remove:
Holder Nuts [A]
Cover [B]
Holder [C]
If the driven gear assembly is to be disassembled, loosen

the housing locknut [A].
Special Tools - Socket Wrench: 57001-1363 [B]
Pinion Gear Holder: 57001-1281 [C]
• Remove:
Driven Gear Assembly [A]
Driven Gear Shim(s) [B]
FINAL DRIVE 12-25
Bevel Gear Case
• Remove:
Housing Locknut
Bearing Housing [A]
Special Tools - Socket Wrench: 57001-1363 [B]
Pinion Gear Holder: 57001-1281 [C]
• Remove:
Driven Gear Shaft Nut [A]
○Pressing the spring seat [C], remove the driven gear shaft
nut.
• Remove:
Bearing Holder [A]
Special Tool - Hexagon Wrench, Hex 40: 57001-1324 [B]
• Remove:
Ball Bearings
Special Tools - Oil Seal & Bearing Remover: 57001-1058
Bearing Driver Set: 57001-1129
Bevel Gear Case Assembly

• Install the housing locknut [A] so that the chamfered side
[B] faces to the bearing.
Driven Gear Shaft Nut
Bearing Holder
Housing Locknut
• Tighten:
Torque - Driven Gear Shaft Nut: 110 N·m (11 kgf·m, 80 ft·lb)
Bearing Holder: 120 N·m (12 kgf·m, 87 ft·lb)
Housing Locknut: 120 N·m (12 kgf·m, 87 ft·lb)
Bevel Gear Case Holder Nuts: 25 N·m (2.5 kgf·m,
18 ft·lb)
• Grease:
Holder Oil Seal Lips
12-26 FINAL DRIVE
Bevel Gear Case
Drive Bevel Gear Removal
• Remove:
Hi/Low Gear Case
Drive Gear Nut [A]
Special Tool - Transmission Gear Holder [B]:
57001-1364 (KAF950-B1 ∼ B3)
57001-1676 (KAF950B6F ∼)
• Remove:
Drive Gear [A]
Drive Gear Shim(s) [B]
Drive Gear Shaft [C]
Drive Bevel Gear Installation

• Check and adjust the bevel gear backlash and tooth con-
tact when any of the backlash-related parts are replaced
(see Bevel Gear Adjustment).
• Apply molybdenum disulfide oil:
Drive Gear Nut Seating Surface
Torque - Drive Gear Nut: 120 N·m (12 kgf·m, 87 ft·lb)
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 correct sequence, using the
procedures shown.
Backlash Adjustment
•Check and adjust the gear backlash when any of the
backlash-related parts are replaced with new ones.
•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.
•Clean any dirt and oil off the bevel gear teeth.
•Install the bevel gear case and tighten the case bolts.
○Check the backlash while tightening the case bolts. Stop
tightening them immediately if the backlash disappears
and change the shim to a thinner one.
FINAL DRIVE 12-27
Bevel Gear Case
• Set up a dial gauge [A] against one of the grooves in the

locknut [B].
• To measure the backlash, turn the shaft clockwise and
counterclockwise while holding the drive bevel gear
steady. The difference between the highest and lowest
gauge readings is the amount of backlash.
Special Tool - Transmission Gear Holder [C]:
57001-1364 (KAF950-B1 ∼ B3)
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).
Change the thickness a little at a time.
• Recheck the backlash, and readjust as necessary.
Bevel Gear Backlash
Standard: 0.08 ∼ 0.18 mm (0.0031 ∼ 0.0071 in.) (at
housing locknut groove)
KAF950B6F ∼
•Hold the driven gear shaft [A] with a vise.
○Protect the driven gear shaft with aluminium plates [B].
•Set up a dial gauge [C] against the middle point [D] of the
gear dog side [E].
○The middle point is position at about 23.5 mm (0.925 in.)
[F] from center.
Gear Dog [G]
•To measure the backlash, turn the shaft clockwise and
counterclockwise. The distance between the highest and
lowest gauge reading is the amount of backlash.
12-28 FINAL DRIVE
Bevel Gear Case
Bevel Gear Case (Backlash-Related Parts)
1. Driven Gear Shaft

2. Bearing Housing
3. Driven Gear Shim(s)
4. Bevel Gear Case
5. Ball Bearing
6. Driven Bevel Gear
7. Hi/Low Gear Case
8. Drive Gear Shaft
9. Ball Bearing
10. Drive Gear Shim(s)
11. Gasket
12. Drive Bevel Gear
13. KAF950B6F ∼
F: Front
FINAL DRIVE 12-29
Bevel Gear Case
Drive Gear Shims [3] Drive Gear Shims [10]

Thickness Part Number Thickness Part Number
0.1 mm (0.0039 in.) 92025-1859 0.15 mm (0.0059 in.) 92025-1573
0.15 mm (0.0059 in.) 92025-1860 0.2 mm (0.0079 in.) 92025-1574
0.5 mm (0.0197 in.) 92025-1861 0.7 mm (0.028 in.) 92025-1534
0.8 mm (0.031 in.) 92025-1862 0.8 mm (0.031 in.) 92025-1535
1.0 (primary, 0.039 in.) 92025-1858 0.9 mm (0.035 in.) 92025-1536
1.2 mm (0.047 in.) 92025-1863 1.0 (primary, 0.039 in.) 92025-1537
1.1 mm (0.043 in.) 92025-1575
1.2 mm (0.049 in.) 92025-1538
1.3 mm (0.051 in.) 92025-1533
Tooth Contact Adjustment

• Clean any dirt and oil off the bevel gear teeth.
• Apply checking compound to 4 or 5 teeth on the driven
bevel gear.
NOTE
○Apply 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.
○The checking compound must be smooth and firm with
the consistency of tooth paste.
○Special compounds are available from automotive sup-
ply stores for the purpose of checking differential gear
tooth patterns and contact. Use this for checking the
bevel gears.
• 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.
• 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.
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
○If the backlash is out of the standard range after chang-
ing shims, correct the backlash before checking the
tooth contact pattern.
[A] Drive Bevel Gear
[B] Driven Bevel Gear
[C] Bottom
[D] Top
[E] Heel
[F] Toe
12-30 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.
[C] Bottom
[D] Top
[E] Heel
[F] Toe
Example 2: Decrease the thickness of the drive bevel

gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the
thickness 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.
[C] Bottom
[D] Top
[E] Heel
[F] Toe
Bevel Gear Inspection

• Visually check the drive bevel gear [A] and the driven
bevel gear [B] for scoring, chipping, or other damage.
Replace the bevel gears as a set if either gear is dam-
aged.
FINAL DRIVE 12-31
Bevel Gear Case
Ball Bearing/Oil Seal Inspection
it with engine oil.
• Inspect the oil seals.
otherwise damaged.
Damper Inspection
• Visually inspect the driven bevel gear [A], cam follower
[B], spring [C], and shaft [D].
Replace any part that appears damaged.
12-32 FINAL DRIVE
Propeller Shafts
Propeller Shaft Removal
• Remove the brake pipe bracket mounting screw [A] from
the floor in the driver’s cage.
Front [B]
• Remove the following under the driver’s cage.

Brake Pipe Bracket Mounting Bolts [A]
Bracket [B]
Front [C]

• Remove:the engine air cleaner cap.
Remove
• Propeller Shaft Bearing Housing Mounting Bolts [A] and
Nuts
• Move the propeller shaft bearing housing [A] to the out-

side [B].
• Remove:
Front Propeller Shaft
Rear Propeller Shaft [C]
○Each shaft can be removed, individually.
FINAL DRIVE 12-33
Propeller Shafts
Propeller Shaft Installation
• Wipe the old grease off the splines of the propeller shafts,
and grease to them.
• Inspect the propeller shafts.
• Install the fronttopropeller
Apply grease the O-ring [A] on the front pinion gear.
• Install the rear propeller shaft [B] on the front pinion gear.
• shaft. shaft [C] on the rear driven gear
• Install the rear propeller shaft front end [D] on the front
propeller shaft rear end [E], aligning the yoke angles of
the front and rear propeller shafts [F].
•Parallel [G] the propeller shaft bearing housing [H] with
the mounting bracket [I], and tighten the mounting bolts
and nuts.
○Make the 3 mm clearance [J] between the front propeller
shaft and the front pinion gear nut [K].
Front [L]
Propeller Shaft Inspection

• Visually inspect the splines of the propeller shafts.
If they are twisted, badly worn, or chipped, replace the
shafts.
• Check that the universal joint works smoothly without rat-
tling or sticking.
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
• Remove (left side view):
Front Suspension Arm and Steering Knuckle (see Sus-
pension chapter)
Front Radiator Side Cover
Front Axle Cap Bolts [A]
Front Axle [B]
Front Axle Installation

• Wipe the old grease off the splines of the axle and cap oil
seal, and grease them.
• Inspect the axle.
• Be sure to install the spacer [A] and O-ring [B] in the re-
cess of the front final gear case.
• Tighten:
Torque - Drive Shaft Cap Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Rear Drive Shaft and Axle Removal

• Remove:
Rear Wheels (see Wheels/Tires chapter)
Rear Brake Drums (see Brakes chapter)
Rear Brake Panel Assy (see Rear Brake Panel Assy Re-
moval in the Brakes chapter)
Leaf Springs (see Leaf Spring Removal in the Suspen-
sion chapter)
Rubber Bands [A]
Axles [B] and Axle Bracket [C]
• 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.
• Tap [A] the outside of the rear axle [B], and pull it out from
the inside.
FINAL DRIVE 12-35
• Remove:
Drive Shaft Cap Bolts [A]
Drive Shaft [B] and Cap [C]
○Set the differential shift lever into the UN-LOCK position.
Rear Drive Shaft and Axle Installation

• Wipe the old grease off the splines of the drive shafts [A],
axles [B], and cap oil seals, and grease them.
• Inspect the drive shafts and axles.
• Align [C] the yoke angles of the drive shaft and axle.
If the dust boot was removed, install it on the axle so that

the small vent hole [A] on the boot is toward the wheel
side.
• Adjust:
Transmission Oil (see Transmission Oil Change in the
Drive Shaft and Axle Inspection

• Visually inspect the splines of the drive shaft and axle.
If they are twisted, badly worn, or chipped, replace the
drive shaft and/or axle with a new one.
• Check that the universal joint and/or ball joint works
smoothly without rattling or sticking.
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
Dust Boot Inspection
• Visually inspect the boots [A] if the drive shafts or axles
are noisy during operation.
If the dust boot is torn, worn, or deteriorated, replace it.
Front Axle Joint Boot Replacement

• Remove:
Front Axle (see Front Axle Removal)
Circlip [A]
• Remove:
Collar [C]
Cap [D]
• Unlock the boot bands [A] for the inboard joint boot and
move [B] the boot toward the outboard joint.
• Remove:
Retaining Ring [A]
• Separate the outboard shaft [B] from inboard shaft [C].
FINAL DRIVE 12-37
• Remove the steel balls [A] with a screwdriver [B].

• Wipe the old grease.
CAUTION
Do not reuse the old grease.
• Move the steel ball holder [C] toward the outboard joint.
• Remove:
Circlip [A]
• Remove:
Steel Ball Base [C]
• Remove:
Inboard Joint Boot [A]
Boot Band [B]
• Discard the old grease.
• Unlock the boot band [A] for the outboard joint boot and
remove the boot [B].
NOTE
○The outboard joint [A] can not be disassembled.
• Wipe the old grease.
12-38 FINAL DRIVE
• Check the universal joints.

If any joint does not work smoothly without rattling or stick-
ing, the joint bearing is damaged. Replace the axle.
• Visually inspect the splines on the shaft.
If they are badly worn or chipped, replace the axle.
• Clean off the joint parts.
CAUTION
Never clean the boots with mineral oil or gasoline
because they will deteriorate the boot.
• Replace the following parts with new ones.

Joint Boots
Circlip
Boot Bands
• Install:
Outboard Joint Boot [A]
• Pack the 1/3 ~ 1/2 of the outboard capacity with 40 ±10 g
of the special grease.
CAUTION
Be sure to use the special grease in the boot set.
• Install the outboard boot [A] on the outboard joint and

shaft [B] properly as shown.
• Clamp the boot bands [C] and bend [D] the tangs [E] se-
curely to hold down the end of the band.
FINAL DRIVE 12-39
• Install:
Small Boot Band [A]
Inboard Boot [B]
Steel Ball Holder [C]
Steel Ball Base [D]
○Install the steel ball holder [A] as shown.

○Face the chamfered side [B] of the steel ball base [C] to
the boot.
Outboard Shaft [D]
• Install:
Circlip [A]
• Align the recesses of the steel ball base and holes in the
steel holder, and install the steel balls [A].
•○Pack the inboard joint with 35 ±10 g of the special grease.

Pack about 25 g of the special grease in the inboard shaft
housing [A].
CAUTION
Be sure to use the special grease in the boot set.
12-40 FINAL DRIVE
• Install the retaining ring [A] so that the opening [B] is

aligned with one of the projections [C].
• Install the inboard boot [A] on the outboard joint and shaft
[B] properly as shown.
[C] 119 mm
• Clamp the small boot band [D] and bend the tang securely
to hold down the end of the band.
• Slightly open [A] the larger diameter end of the joint boot
to equalize the air pressure inside the boot.
• Clamp the large boot band [A] and bend the tang securely
to hold down the end of the band.

it with engine oil.
FINAL DRIVE 12-41
Grease Seal Inspection
• Visually inspect the grease seals.
Replace if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened, or been oth-
erwise damage.
BRAKES 13-1
Brakes
Table of Contents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-6
Special Tools .......................................................................................................................... 13-7
Brake Fluid ............................................................................................................................ 13-8
Brake Fluid Recommendation........................................................................................... 13-8
Brake Fluid Level Inspection ............................................................................................ 13-8
Brake Fluid Change .......................................................................................................... 13-8
Brake Line Air Bleeding ................................................................................................... 13-8
Brake Pedal and Master Cylinder .......................................................................................... 13-10
Brake Pedal Play Inspection ............................................................................................. 13-10
Master Cylinder Removal.................................................................................................. 13-10
Master Cylinder Installation............................................................................................... 13-10
Master Cylinder Disassembly/Assembly........................................................................... 13-10
Master Cylinder Inspection .............................................................................................. 13-11
Brake Hoses and Pipes .......................................................................................................... 13-12
Brake Hose and Pipe Inspection....................................................................................... 13-12
Brake Hose and Pipe Replacement.................................................................................. 13-12
Brake Drums........................................................................................................................... 13-13
Brake Drum Removal........................................................................................................ 13-13
Brake Drum Installation..................................................................................................... 13-13
Brake Drum Wear ............................................................................................................. 13-14
Brake Panel Assemblies......................................................................................................... 13-15 13
Brake Panel Assy Removal .............................................................................................. 13-15
Brake Panel Assy Installation ........................................................................................... 13-16
Brake Panel Disassembly ................................................................................................. 13-16
Brake Panel Assembly...................................................................................................... 13-18
Wheel Cylinder Removal/Installation ................................................................................ 13-20
Wheel Cylinder Assembly ................................................................................................. 13-20
Wheel Cylinder Inspection ................................................................................................ 13-21
Brake Shoe Lining Wear ................................................................................................... 13-21
Brake Shoe Spring Inspection .......................................................................................... 13-21
Parking Brake Lever and Cables............................................................................................ 13-22
Grease Seal Replacement................................................................................................ 13-22
Parking Brake Lever Travel Adjustment .......................................................................... 13-22
Parking Brake Cable Lubrication/Inspection ..................................................................... 13-22
13-2 BRAKES
Exploded View
Front Brake
BRAKES 13-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Bleed Valves 5.9 0.60 52 in·lb
2 Push Rod Locknut 18 1.8 13 cylinder
3 Brake Hose Banjo Bolts 25 2.5 18
4 Brake Pipe Nipples 18 1.8 13
5 Piston Stop Bolt 8.8 0.90 78 in·lb cylinder
6 Reservoir Clamp Bolt 5.9 0.60 52 in·lb
7 Front Axle Nut 200 20 140
8 Wheel Cylinder Mounting Bolts 11 1.1 95 in·lb front
9 Brake Panel Mounting Bolts 44 4.5 33 L
10 Master Cylinder Reservoir Cap 3.4 0.35 30 in·lb
11. Brake master cylinder
12. Brake pedal
13. Right front brake drum
14. Left front brake drum
F: Apply brake fluid.
G: Apply grease.
HG: Apply grease to the right and left sides (Amco Rykon Premium Grease No. 2 EP Green).
L: Apply a non-parmanent locking agent.
R: Replace Part
RL: Apply rubber lubricating oil.
13-4 BRAKES
Exploded View
Rear Brake
BRAKES 13-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Bleed Valves 5.9 0.60 52 in·lb
2 Brake Pipe Nipples 18 1.8 13
3 Rear Axle Nut 300 31 220
4 Wheel Cylinder Mounting Nuts 7.8 0.80 69 in·lb rear
5 Brake Panel Mounting Bolts 44 4.5 33 L
6. Parking brake lever
7. Right rear brake drum
8. Left rear brake drum
9. Right parking brake lever linkage
10. Left parking brake lever linkage
EO: Apply engine oil.
F: Apply brake fluid.
G: Apply grease.
HG: Apply grease to the right and left sides (Amoco Rykon Premium Grease No. 2 EP Green).
R: Replace Parts
RL: Apply rubber lubricating oil.
W: White mark
Y: Yellow mark
13-6 BRAKES
Specifications

Brake Fluid
Grade 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 180.75 mm
(7.0866 ∼ 7.0929 in.) (7.116 in.)
Brake Panel Assemblies
Brake Shoe Lining Thickness 4.5 mm (0.18 in.) 1.0 mm (0.04 in.)
Parking Brake Lever and Cables
Parking Brake Lever Travel 8 ∼ 12 notches (clicks) – – –
at 200 N (20 kgf, 44 lb)
BRAKES 13-7
Special Tools
Rotor Puller, M16/M18/M20/M22 × 1.5: Brake Drum Holder:
57001-1216 57001-1325
Brake Drum Remover: Brake Drum Remover Nuts:

57001-1260 57001-1326
Brake Drum Pusher, M18 × 1.5: Grease Seal Driver Set:

57001-1261 57001-1629
13-8 BRAKES
Brake Fluid
Brake Fluid Recommendation
• Use extra heavy-duty brake fluid only from a container
marked DOT3.
Recommended Brake Fluid
Grade: DOT3
WARNING
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. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
Don’t leave the reservoir 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.
CAUTION
diately.
Brake Fluid Level Inspection

• Refer to the Brakes in the Periodic Maintenance chapter.
Brake Fluid Change
Brake Line Air Bleeding
Front [C]
• Level the reservoir and check that there is plenty of fluid
in the reservoir.
NOTE
○The 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.
• 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.
BRAKES 13-9
Brake Fluid
• Remove
chapter).
the wheel for extra clearance (see Wheels/Tires
• Connect a clear plastic hose [A] to the bleed valve at the

wheel cylinder, running the other end of the hose into a
container.
NOTE
○Start with the rear left or right wheel and finish with the
front left or right wheel.
Left Front Brake Panel [B]
Front [C]
•○Bleed the brake line and the caliper as follows:

Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake pedal until it 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.
• Tighten:
Torque - Bleed Valves: 5.9 N·m (0.6 kgf·m, 52 in·lb)
• Repeat the previous step for each wheel.
• level in thebleeding
When air is finished, add fluid up to the upper
reservoir.
• for fluid leakage forcefully
Apply the brake for a few seconds, and check
around the fittings.
Torque - Master Cylinder Reservoir Cap: 3.4 N·m (0.35
kgf·m, 30 in·lb)
13-10 BRAKES
Brake Pedal and Master Cylinder
Brake Pedal Play Inspection
Master Cylinder Removal
Front [C]
• Remove:
Brake Hose Banjo Bolts [A]
Brake Pipe Nipple [B] (unscrew)
CAUTION
diately.
• Remove:
Master Cylinder Mounting Bolts [C] and Master Cylinder
[D]
Front [E]
Master Cylinder Installation
• Use a new flat washer on each side of the brake hose
fitting.
• Apply brake fluid to the brake pipe nipple threads.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Bleed the brake line after master cylinder installation.
• Adjust the brake pedal play (see Brake Pedal Play Inspec-
tion in the Periodic Maintenance chapter).
• Check that the brake line has proper fluid pressure and
no fluid leakage.
Master Cylinder Disassembly/Assembly
• Refer to the Brake Master Cylinder Cup and Dust Seal
Replacement in the Periodic Maintenance chapter.
BRAKES 13-11
Brake Pedal and Master Cylinder
Master Cylinder Inspection
• Disassemble the master cylinder (see Brake Master
Cylinder Cup and Dust Cover Replacement in the Peri-
odic Maintenance chapter).
• Check that there are no scratches, rust or pitting on the
inside of the cylinder [A] and on the outside of the pistons
[B].
If the cylinder or piston shows any damage, replace them.
• Inspect the primary cups [C] and secondary cups [D].
If a cup is worn, damaged, softened (rotted), or swollen,
replace it.
If fluid leakage is noted at the brake push rod, the sec-
ondary cup of the rear piston should be replaced.
• Check the dust cover [E] for damage.
If it is damaged, replace it.
• Check that the relief [F] and supply [G] ports are not
plugged.
If the small relief port becomes plugged, the brake shoes
will drag on the drum. Blow the ports clean with com-
pressed air.
• Check the piston return springs [H] for any damage.
If the spring is damaged, replace it.
13-12 BRAKES
Brake Hoses and Pipes
Brake Hose and Pipe Inspection
Brake Hose and Pipe Replacement
BRAKES 13-13
Brake Drums
Brake Drum Removal
• Remove:
Wheel (see Wheel Removal in the Wheels/Tires chap-
ter).
Cotter Pin [A]
Axle Nut [B]
○Loosen the axle nut, while applying the brake, and release
the brake.
○You can also loosen the axle nut, using the brake drum
holder (special tool).
Special Tool - Brake Drum Holder: 5700-1325
• Be sure to release the parking brake when removing the
rear brake drum.
• The brake drums are press-fitted on the axles. Use the

brake drum remover set and rotor puller (special tools) to
remove the drums.
○Mount 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 × 1.5: 57001
-1216 [A]
Brake Drum Remover: 57001-1260 [B]
Brake Drum Remover Nuts: 57001-1326 [C]
Washers [D]
○Do not remove the drum bolts. If a drum bolt is damaged,
replace the drum.
Brake Drum Installation
• Grease (Amoco Rykon Premium Grease No.2 EP Green)
the brake drum grease seal lips [A] and inside [B] of the
drum as shown.
Grease Seal [C]
Brake Drum [D]
• Install:
Collar [A] (Rear only)
Brake Drum
13-14 BRAKES
Brake Drums
• Observe
drums.
the following procedure to install the brake
○Apply a grease to the splines on the drum.

○Mount the brake drum holder [A] securely on the drum
studs with the wheel nuts.
○Using the brake drum pusher [B], drive the drum onto the
axle until the pusher stops.
Special Tools - Brake Drum Pusher, M18 × 1.5: 57001-1261
Brake Drum Holder: 57001-1325
Replace the drum with a new one if its maximum press
-fitting force (torque) is less than the service limit because
the drum inside diameter will be dulled.
Drum Press-fitting Force (Torque)
Service Limit: 20 N·m (2.0 kgf·m, 14 ft·lb)
○Apply a molybdenum disulfide lubricant (grease or oil

type, either will do) to the threads and the seating surface
of the axle nut.
○Drive the drum further using the axle nut and washer in-
stead of the pusher until the drum stops. At this time, use
a torque wrench to turn the axle nut. Note the driving force
(torque) of the nut.
The drum must be press-fitted on the axle. If the max-
imum torque for driving the nut is less than the service
limit of the drum press-fitting force (torque), the drum will
not be tight enough and must be replaced.
If the maximum torque for driving the nut is more than the
service limit, the drum is normal. Retighten the axle nut
to the specified torque as follows:
○Remove the brake drum holder (special tool).
• Tighten:
Torque - Front Axle Nuts: 200 N·m (20 kgf·m, 140 ft·lb)
Rear Axle Nuts: 300 N·m (31 kgf·m, 220 ft·lb)
• Insert a new cotter pin [A].
NOTE
○When 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.
○It should be within 30 degree.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut. [B]

WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.
Brake Drum Wear

BRAKES 13-15
Brake Panel Assy Removal
(Front Brake Panel)
• Remove:
Front Brake Drum (see Brake Drum Removal in this
chapter)
Breather Hose [A]
Brake Pipe Nipple [B]
Front [C]
○Immediately wipe up any brake fluid that spills.
CAUTION
diately.
• Remove the brake panel mounting bolts [A], and then re-
move the brake panel assembly [B].
(Rear Brake Panel)

• Remove:
Rear Brake Drum [A] (see Brake Drum Removal)
Vent Hose [B]
Cotter Pin and Clevis Pin [C]
Brake Pipe Nipple [D] (unscrew)
CAUTION
diately.
• Remove the brake panel mounting bolts [A] and collar [B]
and then remove the brake panel assy [C].
13-16 BRAKES
Brake Panel Assy Installation
(Front and Rear Brakes)
• Grease (Amoco Rykon Premium Grease No.2 EP Green):
Brake Panel Seating Surface (between axle and panel)
• Install the brake panel assy.
Brake Panel Mounting Bolts
Torque - Brake Panel Mounting Bolts: 44 N·m (4.5 kgf·m,
33 ft·lb)
• Apply brake fluid to the threads of the brake pipe nipple
and tighten it.
• Bleed the brake line after brake drum installation (see

Brake Line Air Bleeding in this chapter).
power, no brake drag, and no fluid leakage.
WARNING
• Inspect and if necessary adjust:

Parking Brake Lever Inspection (see Parking Brake
Lever Inspection in the Periodic Maintenance chapter).
Brake Panel Disassembly
(Front Brake Panel)
• Remove:
Front Brake Drum (see this chapter)
Brake Pipe Nipple and Vent Hose (see Brake Panel Assy
Removal)
• Remove the brake shoe springs [A].
• While pushing the shoe hold-down spring [B], turn the pin
[C] 90° and remove the shoes [D] individually.
NOTE
• Remove the brake panel mounting bolts [E], and then re-
move the brake panel [F].
Front [G]
BRAKES 13-17
(Rear Brake Panel)
• 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]
CAUTION
diately.
• Remove the brake shoe springs [A].

• [C] 90° and remove
While pushing the shoe hold-down spring [B], turn the pin
the shoes [D] individually.
NOTE
○To prevent the rear pin [E] from dropping into the rear axle
bracket, tape the pin onto the brake panel.
• Remove the collar [F] on the rear brake panel.
Front [G]
• Remove the following for rear brake panel removal (left

side view).
Cotter Pin [A]
Clevis Pin [B]
Parking Brake Lever Linkage [C]
• Remove
view).
the brake panel mounting bolts [A] (left side
• Remove the rear brake panel [B].

13-18 BRAKES
Brake Panel Assembly
(Front Brake)
• Grease (Amoco Rykon Premium Grease No.2 Green):
Brake Panel Seating Surface (between axle and panel)
• Install:
Brake Panel and Wheel Cylinder
33 ft·lb)
Wheel Cylinder Mounting Bolts: 11 N·m (1.1 kgf·m,
95 in·lb)
• Grease:
Contact Points [A] of Brake Panel and Brake Shoes
Wheel Cylinder Piston Ends [A]
Brake Shoe Anchor Ends [A]
• Apply brake fluid:
Brake Pipe Nipple Threads
• Tighten:
○The wheel cylinder has a brake shoe clearance adjuster.

• Turn [A] either end of the cylinder fully while holding the
other end [B]. Both ends are put into the cylinder.
• Install the brake shoe springs on the original positions
(see Brake Shoe Spring Inspection in this chapter).
(Rear Brake)
○Grease (Amoco Rykon Premium Gease No.2 EP Green):
Brake Panel Steating Surface (between axle and panel)
• Install:
Brake Panel and Wheel Cylinder
• Grease:
Shoe Clearance Adjuster Pivots [A]
33 ft·lb)
Wheel Cylinder Mounting Nuts: 7.8 N·m (0.80
kgf·m, 69 ft·lb)
• Apply brake fluid to the thread of the brake pipe nipple
and tighten it.
• Grease (see Front Brake Panel Assembly above).
Contact Points of Brake Panel and Brake Shoes
Wheel Cylinder Piston Ends
Brake Shoe Anchor Ends
BRAKES 13-19
• Install the parking brake lever linkage [A] and the grommet
[B] with the tabs [C] up.
• FitBrake
the lips [D] of the grommet as shown.
Panel [E] (top view of the left rear)
• Brake Shoebrake
Install the springs on the original positions (see
Spring Inspection in this chapter).
○The parking brake lever linkage has a brake shoe clear-

ance adjuster.
• 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.

Ratchet [B]
Protruding Position [C]
Front [F]

Ratchet [B]
Original Position [D]
Front [F]
• Pack gaps [A] with grease sparingly.

• (see Brake
Install the brake shoe springs on the original positions
Shoe Spring Inspection in this chapter).
13-20 BRAKES
(Front and Rear Brakes)
• Bleed the brake line after drum installation (see Brake
Line Air Bleeding in this chapter).
power, no brake drag and no fluid leakage.
WARNING
• Inspect and if necessary adjust:

Parking Brake Lever Inspection (see Parking Brake
Lever Inspection in the Periodic Maintenance chapter)
Wheel Cylinder Removal/Installation
• Refer to the Brake Wheel Cylinder Assembly Replace-
ment in the Periodic Maintenance chapter.
Wheel Cylinder Assembly
• 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.
CAUTION
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.
BRAKES 13-21
Wheel Cylinder Inspection
• Remove the wheel cylinder (see Brake Wheel Cylinder
Assembly Replacement in the Periodic Maintenance
chapter).
• Disassemble the wheel cylinder.
• Check that there are no scratches, rust or pitting on the
inside of the cylinder and on the outside of the piston.
If the cylinder or piston shows any damage, replace the
cylinder.
• Inspect the cups.
If a cup is worn, damaged, softened (rotted) or swollen,
replace the cylinder.
If fluid leakage is noted at the dust seals, the cylinder
should be replaced to renew the cup.
• Check the dust covers for damage.
If they are damaged, replace the cylinder.
• Check the spring for any damage.
If the spring is damaged, replace the cylinder.
• Front brake only: Check the brake shoe clearance ad-
juster for damage.
If it shows any damage, replace the cylinder.
Dust Cover [A]
Piston [B]
Cup [C]
Shoe Clearance Adjuster (Front) [D]
Spring (Rear) [E]
Brake Shoe Lining Wear
• Refer to the Brake Wear Inspection in the Periodic Main-
tenance chapter.
Brake Shoe Spring Inspection
(Left Front Brake Panel)
• Visually inspect the brake shoe springs [A] for breaks or
distortion.
If the springs are damaged in any way, replace them.
• Install the shoe springs in the original position shown, not-
ing the hook direction.
• Install the lower spring inside the plate of the shoe.
(Left Rear Brake Panel)

• Install the upper shoe spring in the original position
shown, noting the relative position of the coil to the
parking brake lever linkage.
13-22 BRAKES
Parking Brake Lever and Cables
Grease Seal Replacement
• Remove:
Brake Panel Assembly
Grease Seal [A]
CAUTION
Be careful not to damage the brake panel when re-
moving the grease seal.
• Install the grease seal [A] to specified position as shown.

[B] Top Surface of Grease Seal
[C] Center Bottom of Brake Panel
[D] 11.2 ∼ 12.0 mm (0.44 ∼ 0.47 in.)
NOTE
○If the following special tool (Grease Seal Driver Set) is
used, the position will be secured.
• Apply soapsuds to inside area of the new grease seal.

• bleed valve
Put the brake panel on a suitable flat plate [A] so that the
fitting [B], boss [C] and parking brake lever
linkage [D] (rear only) are not contact to the plate.
• Put the guide [E] in the panel so that the UP mark [F] faces
upward.
Special Tool - Grease Seal Driver Set: 57001-1629
• Put the grease seal [G] on the brake panel evenly.
• Put the grease seal driver [A] on the grease seal evenly.
Special Tool - Grease Seal Driver Set: 57001-1629
• Put the compressor [B] to center on the grease seal driver.
Special Tool - Clutch Spring Compressor: 57001-1162
• Using a press install the grease seal.
• the grease
Grease (Amoco Rykon Premium Grease No.2 EP Green)
seal lips.
Parking Brake Lever Travel Adjustment

Parking Brake Cable Lubrication/Inspection
• Refer to the General Lubrication in the Periodic Mainte-
nance chapter.
SUSPENSION 14-1
Suspension
Table of Contents
Exploded View........................................................................................................................ 14-2
Specifications ......................................................................................................................... 14-4
Special Tool ............................................................................................................................ 14-5
Struts and Rear Shock Absorbers .......................................................................................... 14-6
Strut (Front Shock Absorber) Removal............................................................................. 14-6
Strut (Front Shock Absorber) Installation.......................................................................... 14-6
Strut Spring Replacement................................................................................................. 14-7
Rear Shock Absorber Preload Adjustment ....................................................................... 14-8
Rear Shock Absorber Removal ........................................................................................ 14-9
Rear Shock Absorber Installation ..................................................................................... 14-9
Shock Absorber Inspection ............................................................................................... 14-9
Front Suspension Arms .......................................................................................................... 14-10
Front Suspension Arm Removal ....................................................................................... 14-10
Front Suspension Arm Installation .................................................................................... 14-10
Front Suspension Arm Inspection..................................................................................... 14-11
Leaf Springs and Dampers..................................................................................................... 14-12
Leaf Spring Removal ........................................................................................................ 14-12
Leaf Spring Installation ..................................................................................................... 14-12
Leaf Spring Inspection ...................................................................................................... 14-13
14
14-2 SUSPENSION
Exploded View
SUSPENSION 14-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Strut Mounting Nuts 44 4.5 33
2 Strut Clamp Nut 98 10 72
3 Rear Shock Absorber Mounting Nuts 59 6.0 43
4 Strut Locknut 49 5.0 36
5 Front Suspension Arm Pivot Bolts 98 10 72
6 Front Suspension Arm Joint Nut 78 8.0 58
7 Damper Bracket Mounting Nuts 44 4.5 33
8 Leaf Spring Mounting Nuts (Front) 98 10 72
9 Leaf Spring Mounting Nuts (Rear) 59 6.0 43
10. Left rear shock absorber
11. Right rear shock absorber
12. Knuckle joint
G: Apply grease.
HG: Apply grease (Amoco Rykon Premium Grease No. 2 EP Green).
R: Replacement Parts
14-4 SUSPENSION
Specifications

Rear Shock Absorbers (Usable Range)
Spring Preload Setting Position 3rd position 1 ∼ 5 positions
SUSPENSION 14-5
Special Tool
Steering Stem Nut Wrench:
57001-1100
14-6 SUSPENSION
Struts and Rear Shock Absorbers
Strut (Front Shock Absorber) Removal
• Remove:
Front Fender Upper (see Frame chapter)
Front Wheel (see Wheels/Tires chapter)
Brake Panel Assy (see Brake Panel Assy Removal in
the Brakes chapter).
Brake Hose Retainer [A]
Brake Hose [B] and Vent Hose [C] (from Bracket)
Strut Clamp Bolt and Nut [D]
Front [E]
• Remove:
Strut Mounting Nuts [A]
Front [B]
• Remove the strut [A] from the steering knuckle [B].

Front [C]
Strut (Front Shock Absorber) Installation

• Insert the strut into the steering knuckle [A] while aligning
the notch [B] on the strut with the clamp bolt hole [C] on
the steering knuckle.
• Tighten:
Torque - Strut Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb)
Strut Clamp Nut: 98 N·m (10 kgf·m, 72 ft·lb)
• Insert a new cotter pin [A]

NOTE
not align with the cotter pin hole in the bolt, tighten the
nut clockwise [B] up to next alignment.
○Loosen once and tighten again when the slit goes past
the nearest hole.
SUSPENSION 14-7
• 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.
• Remove:
Strut (see Strut Removal)
• Hold the large washer [A] in a vise [B].
• Remove:
Locknut [C] and Small Washer
Large Washer
• Remove:
Holder [A]
Thrust Plate [B]
Dust Seal
Thrust Washer
Upper Spring Seat [C]
Dust Cover [D]
Spring [E]
•○Install the new spring.

Fit the spring end [A] to the bulge [B] in the lower spring
seat [C].
• Install:
Dust Cover [A]
Upper Spring Seat [B]
○Fit the spring end to the bulge [C] in the dust cover and
upper spring seat.
14-8 SUSPENSION
• Apply grease to the upper and lower side on the following

parts, and install them.
Dust Seal [A]
Thrust Washer [B]
○Face the projection on the thrust washer downward.
• Install:
Holder [A]
Large Washer [B]
Small Washer [C]
Locknut [D]
○Push down the holder, and tighten the locknut.
Torque - Strut Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)
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 ac-
tion feels too soft or too stiff, adjust it in accordance with the
following table.
Spring Action
Spring
Position Setting Load Terrain Speed
Force
1 Soft Light Smooth Low
2 ↑ ↑ ↑ ↑
3 (STD)
4 ↓ ↓ ↓ ↓ ↓
5 Stronger Hard Heavy Rough High
• Turn the adjusting sleeve on each rear shock absorber to

the desired position with the wrench [A].
Special Tool - Steering Stem Nut Wrench: 57001-1100
○Both adjusting sleeves (left and right) must be turned to
the same relative position.
WARNING
If both adjusting sleeves are not adjusted equally,
handling may be impaired and a hazardous condi-
tion may result.
SUSPENSION 14-9
Rear Shock Absorber Removal
• Remove:
Rear Wheel (see Wheels/Tires chapter)
• Remove:
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

• Install the rear wheel temporarily and ground it to load the
suspension.
• Tighten:
Torque - Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 43 ft·lb)
Shock Absorber Inspection

• Visually
tion.
inspect the shock absorber for breaks or distor-
If the shock absorber is damaged in any way, replace it.

• Check for oil leakage at the shock absorber damper unit.
If oil leakage is noted, the shock absorber should be re-
placed to renew the oil seal.
• Visually inspect the rubber bushings in the upper and/or
lower mountings of the rear shock absorber.
If they are worn, cracked, hardened, or otherwise dam-
aged, replace them with new ones.
14-10 SUSPENSION
Front Suspension Arms
Front Suspension Arm Removal
• Remove:
Front Wheel (see Wheels/Tires chapter)
Brake Panel Assy [A] (see Brake Panel Assy Removal
in the Brakes chapter)
• Hold the front brake drum and panel assembly in position.
• Remove:
Front Suspension Arm Pivot Bolts [B]
Front [C]

Front Suspension Arm Joint Nut [A]
• Remove the front suspension arm [B] along with the steer-
ing knuckle [C] off the front axle [D].
• Install a suitable nut [A] on the stud of the tie-rod end

joint [B] and tap the nut to free the joint from the steering
knuckle [C].
○The front suspension arm [D] comes off the steering
knuckle.
Front Suspension Arm Installation

• Clean the tapered portion of the front suspension arm joint
and the tapered hole of the steering knuckle, or the tapers
will not fit snugly.
• Grease:
Front Suspension Arm Joint Boot Sealing Surface [A]
Good [B] Bad [C]
• When the front suspension arm pivot bolts are tightened,

install the arm joint in the steering knuckle to position the
arm within its operating angle.
• Tighten:
Torque - Front Suspension Arm Pivot Bolts: 98 N·m (10
kgf·m, 72 ft·lb)
Front Suspension Arm Joint Nut: 78 N·m (8.0
kgf·m, 58 ft·lb)
SUSPENSION 14-11
Front Suspension Arms

NOTE
not align with the cotter pin hole in the joint, tighten the
nut clockwise [B] up to next alignment.
the nearest hole.
Front Suspension Arm Inspection

• Visually inspect the front suspension arm for breaks or
distortion.
If the front suspension arm is damaged in any way, re-
place it.
• Check the rubber bushings in the pivots.
Replace any bushings that are worn, cracked, hardened,
or otherwise damaged.
14-12 SUSPENSION
Leaf Springs and Dampers
Leaf Spring Removal
• Remove:
Rear Wheel (see Wheels/Tires chapter)
• Support the rear axle housing on a jack [A].
• plug it. the brake pipe nipple from the brake panel and
Unscrew

CAUTION
diately.
• Cut the straps [B] and free the vent hose and the brake
hose from the leaf spring.
• Tilt up the cargo bed (see Frame chapter).
• Remove:
Converter Air Cleaner Housing (see Converter System
chapter).
Rear Shock Absorber [C]
Damper Bracket Mounting Nuts [D]
Damper and Bracket [E]
Front [F]
• Remove:
Clamp [A]
Leaf Spring Mounting Bolts and Nuts [B]
Leaf Spring [C]
Front [D]
Leaf Spring Installation

• When installing the rubber bushings in the mounts of the
leaf spring, lubricate them with a soap and water solution.
CAUTION
Do not use engine oil or petroleum distillates to lu-
bricate the bushings because they will deteriorate
the rubber.
• Tighten:
Torque - Damper Bracket Mounting Nuts: 44 N·m (4.5
kgf·m, 33 ft·lb)
• Install the rear wheel temporarily and ground it to load the
suspension during the mounting nut tightening.
• Tighten:
Torque - Leaf Spring Mounting Nuts (front): 98 N·m (10
kgf·m, 72 ft·lb)
Leaf Spring Mounting Nuts (rear): 59 N·m (6.0
kgf·m, 43 ft·lb)
Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 43 ft·lb)
• Bleed the brake line (see Brakes chapter).
SUSPENSION 14-13
Leaf Springs and Dampers
Leaf Spring Inspection
• Visually inspect the leaf spring for breaks or distortion.
If the leaf spring is damaged in any way, replace it.
• Check the rubber bushings in the mounts and the damper.
Replace any bushings or damper that are worn, cracked,
hardened, or otherwise damaged.
STEERING 15-1
Steering
Table of Contents
Exploded View........................................................................................................................ 15-2
Specifications ......................................................................................................................... 15-4
Steering Wheel and Main Shaft Assembly ............................................................................. 15-5
Steering Wheel Position Adjustment................................................................................. 15-5
Steering Wheel Free Play Inspection................................................................................ 15-5
Steering Wheel Centering................................................................................................. 15-5
Steering Wheel and Steering Shaft Removal ................................................................... 15-5
Steering Wheel and Main Shaft Installation ...................................................................... 15-6
Steering Gear Assembly......................................................................................................... 15-7
Steering Gear Assembly Removal.................................................................................... 15-7
Steering Gear Assembly Installation................................................................................. 15-7
Steering Gear Preload Adjustment ................................................................................... 15-8
Tie-rod Length Adjustment................................................................................................ 15-9
Dust Boot Inspection......................................................................................................... 15-9
Steering Knuckles................................................................................................................... 15-10
Steering Knuckle Removal................................................................................................ 15-10
Steering Knuckle Installation............................................................................................. 15-10
15
15-2 STEERING
Exploded View
STEERING 15-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Steering Wheel Mounting Nut 52 5.3 38
2 Intermediate Shaft Clamp Bolts 20 2.0 14
3 Steering Gear Assembly Bracket Bolts 52 5.3 38 L
4 Tie-rod End Nuts 34 3.5 25
5 Rack Guide Spring Cap Locknut 39 4.0 29
6 Tie-rod End Locknuts 49 5.0 36
7 Strut Clamp Nut 98 10 72
8. Steering gear assembly
9. Horn switch
10. Steering wheel
11. Horn switch contact
12. Steering knuckle
G: Apply grease to the lips of the grease seal or rubber boots.
HG: Apply grease (Amoco Rykon Premium Grease No. 2 EP Green).
15-4 STEERING
Specifications

Steering Wheel
Steering Wheel Free Play 0 ∼ 20 mm (0 ∼ 0.79 in.) – – –
Steering Gear Assembly
Tie-rod Length 51.5 mm (2.03 in.) – – –
(Distance Between Groove and
Locknut)
STEERING 15-5
Steering Wheel and Main Shaft Assembly
Steering Wheel Position Adjustment
• Loosen the steering main shaft mounting nuts [A].
• Tighten thesteering
Adjust the wheel position.
• main shaft mounting nuts securely.
Steering Wheel Free Play Inspection

• Refer to Steering Inspection in the Periodic Maintenance
chapter.
Steering Wheel Centering
• Test ride the vehicle.
If the steering wheel is not straight when the vehicle is
traveling in a straight line, do the following.
• Check the tie-rod length and adjust it if necessary (see
Wheels/Tires chapter).
• Remove the cap [A] and the horn switch [B], and then
loosen the steering wheel mounting nut [C].
• Push the vehicle in a straight line with no one aboard, and
stop it without turning the steering wheel.
• Remount the steering wheel [D] so that it is straight
ahead.
Torque - Steering Wheel Mounting Nut: 52 N·m (5.3 kgf·m,
38 ft·lb)
Steering Wheel and Steering Shaft Removal

• Remove (see above):
Wheel Cap and Horn Switch (see above)
Steering Wheel Mounting Nut and Spring Washer
Steering Wheel
• Remove:
Screws [A] and Horn Switch Contact [B]
Two Straps [C] of Horn Switch Body Lead
Front [D]
• Remove:
Main Shaft Mounting Bolts, Washers and Nuts [A]
Main Shaft Clamp Bolt [B]
• Lift the main shaft [C].
15-6 STEERING
Steering Wheel and Main Shaft Assembly
• Remove:
Steering Gear Shaft Clamp Bolt [A]
• Front
Lift the intermediate shaft [B].
[C]
Steering Wheel and Main Shaft Installation

• Grease:
Dust Cover Lips [A]
• Connect the intermediate shaft [A] to the main shaft [B]

with the steering gear pinion in any position.
• Mount the steering wheel on the main shaft temporarily.
• Adjust:
Steering Wheel Position Adjustment
Steering Wheel Centering
• Tighten:
Torque - Intermediate Shaft Clamp Bolts [C]: 20 N·m (2.0
kgf·m, 14 ft·lb)
Steering Wheel Mounting Nut: 52 N·m (5.3 kgf·m,
38 ft·lb)
Front [D]
• Install the horn switch [A] as shown.

STEERING 15-7
Steering Gear Assembly Removal
• Remove:
Front Wheels (see Wheels/Tires chapter)
Steering Wheel and Main Shaft (see this chapter)
Front Radiator (see Cooling System chapter)
Tie-rod End Nuts [A] and Tie-rod Ends [B] from Steering
Knuckles
Front [D]
○Install a suitable nut on the stud of the tie-rod end joint
and tap the nut to free the joint from the steering knuckle.
CAUTION
Do not loosen the tie-rod end locknuts [C], or the
toe-in of the front wheels will be changed.

Radiator Side Cover (Left) [A]
Coolant Hose [B]
Coolant Pipe [C] (see Front Final Gear Case Removal
in the Final Drive chapter)
Boot [D]
Vent Hose [E] of Front Final Gear Case
Horn Ground Lead Terminal [F]
Steering Gear Assembly Bracket Bolts [G] and Brackets
• Remove:
Steering Gear Assembly [A]
Front [B]
Steering Gear Assembly Installation

• Adjust if necessary:
Steering Gear Preload Adjustment
Tie-rod Length Adjustment
• 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.
• Grease:
Tie-rod End Joint Boot Sealing Surfaces [A]
Good [B] Bad [C]
15-8 STEERING
• Install
forward.
the boot [A] so that the mark (F, Arrow) [B] faces
• Tighten:
Torque - Steering Gear Assembly Bracket Bolts: 52 N·m
(5.3 kgf·m, 38 ft·lb)
Tie-rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
○Tighten the steering gear assembly bracket bolts evenly.
• Check:
Toe-in of Front Wheels (see Wheels/Tires chapter)

NOTE
not align with the cotter pin hole in the clamp bolt or
joint, tighten the nut clockwise [B] up to next alignment.
the nearest hole.
Steering Gear Preload Adjustment

• Loosen the locknut [A].
• kgf·m, 61thein·lb)
Tighten rack guide spring cap [B] to 6.9 N·m (0.70
of torque.
• Tighten the locknut60while
Back off the cap ∼ 70°.
• preventing the cap from turning.
Torque - Rack Guide Spring Cap Locknut: 39 N·m (4.0
kgf·m, 29 ft·lb)
Pinion [C] Spring [F]

Rack [D] Top [G]
Rack Guide [E]
STEERING 15-9
Tie-rod Length Adjustment
• Refer to Toe-in Adjustment in the Wheels/Tires chapter.
Tie-rod Length [A]
Front [B]
Dust Boot Inspection

• Refer to the Steering in the Periodic Maintenance chapter.
15-10 STEERING
Steering Knuckles
Steering Knuckle Removal
• Remove the steering knuckle together with the front sus-
pension arm (see Front Suspension Arm Removal in the
Suspension chapter).
•Install a suitable nut [A] on the stud of the tie-rod end
joint [B] and tap the nut to free the joint from the steering
knuckle [C].
○The steering knuckle comes off the front suspension arm
[D].
Steering Knuckle Installation

• Clean the tapered 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, or the
tapers will not fit snugly.
• Grease:
Axle Bearing Grease Seal Lips
Front Suspension Arm Joint Boot Sealing Surfaces [A]
Good [B] Bad [C]
• Tighten:
Torque - Strut Clamp Nut: 98 N·m (10 kgf·m, 72 ft·lb)
Front Suspension Arm Joint Nut: 78 N·m (8.0
kgf·m, 58 ft·lb)
Tie-rod End Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)

NOTE
not align with the cotter pin hole in the clamp bolt or
joint, tighten the nut clockwise [B] up to next alignment.
the nearest hole.

• Check:
Toe-in of Front Wheels (see Wheels/Tires chapter)
FRAME 16-1
Frame
Table of Contents
Exploded View........................................................................................................................ 16-2
Seat and Seat Belts................................................................................................................ 16-8
Seat Removal ................................................................................................................... 16-8
Seat Installation ................................................................................................................ 16-8
Seat Belt Removal ............................................................................................................ 16-8
Seat Belt Installation ......................................................................................................... 16-8
Control Panel.......................................................................................................................... 16-9
Control Panel Removal ..................................................................................................... 16-9
Glove Compartment Removal........................................................................................... 16-10
Front Cargo Compartment...................................................................................................... 16-11
Front Cargo Hood Removal .............................................................................................. 16-11
Front Cargo Compartment Removal................................................................................. 16-11
Cargo Bed .............................................................................................................................. 16-12
Cargo Bed Removal.......................................................................................................... 16-12
Cargo Bed Installation....................................................................................................... 16-12
Front and Rear Bars ............................................................................................................... 16-14
Front Bar Removal............................................................................................................ 16-14
Front Bar Installation......................................................................................................... 16-14
Rear Bar Removal ............................................................................................................ 16-14
Rear Bar Installation ......................................................................................................... 16-14
Cargo Bed Latch Position Inspection................................................................................ 16-15
Cargo Bed Latch Position Adjustment .............................................................................. 16-15
Front Fender Assembly .......................................................................................................... 16-16
Front Guard Removal ....................................................................................................... 16-16
Front Cover Removal........................................................................................................ 16-16
Front Fender Removal ...................................................................................................... 16-17
Radiator Side Cover Removal .......................................................................................... 16-17
Radiator Side Cover Installation ....................................................................................... 16-17
Radiator Side Cover Flap Removal .................................................................................. 16-18 16
Floor Center Panel Removal............................................................................................. 16-18
Rear End Sub-frame............................................................................................................... 16-19
Rear End Sub-frame Removal.......................................................................................... 16-19
Rear End Sub-frame Installation ...................................................................................... 16-19
16-2 FRAME
Exploded View
FRAME 16-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Battery Holder Mounting Nut 17 1.7 12
3. Canada and Australia Models
4. KAF950-B1/B2
5. KAF950-B3, B6F ∼
G: Apply grease.
16-4 FRAME
Exploded View
FRAME 16-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Seat Belt Mounting Bolts 34 3.5 25
2 Front Bar Mounting Bolts (Upper) 44 4.5 33
3 Front Bar Mounting Bolts (Lower) 98 10 72
4 Rear Bar Mounting Bolts And Nuts 44 4.5 33
5 Rear End Sub-frame Mounting Nuts 44 4.5 33
G: Apply grease.
16-6 FRAME
Exploded View
FRAME 16-7
Exploded View
Torque
N·m kgf·m ft·lb
1 Latch Handle 4.4 0.45 39 L
2. Fix the bolt to inside from outside.
3. Large corner side
G: Apply grease.
16-8 FRAME
Seat and Seat Belts
Seat Removal
• Remove:
Seat Bracket Nuts [A]
Seat Brackets [B]
Seat [C]
• Remove:
Seat Back Mounting Nuts [A]
Seat Back [B]
Seat Installation
• Grease:
Seat Bracket Inside Surfaces [A]
• Be careful not to overtighten the seat bracket nuts. After
tightening the nuts, the seat must be moved up and down
smoothly.
Seat Belt Removal

• Remove:
Seat Belt Mounting Bolts [A]
Seat Belts [B]
Seat Belt Buckles [C]
Seat Belt Installation

• Tighten:
Torque - Seat Belt Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
FRAME 16-9
Control Panel
Control Panel Removal
• Remove:
Front Cargo Compartment (see Front Cargo Compart-
ment Removal)
• Disconnect:
Light Switch Wire Connector
Hour Meter Wire Connector
Ignition Switch Wire Connector
Power Outlet Connector Wire Connector
Coolant Temperature Warning/Parking Brake Indicator
Light Wire Connector
Oil Pressure Warning Light Wire Connector
Glow Plug Light Wire Connector
• Remove or disconnect:
Speedometer Indicator Light Connector [A]
Speedometer Cable Upper End [B]
Speedometer Bracket Mounting Bolts [C]
• Remove the speedometer [D] with the bracket from the
control panel.
• Remove:
Control Panel Lower Screws [A] and Collars
• Control Panel Upper Screws [B]
Loosen:
• Open the right glove compartment cover [C].

• Remove:
Control Panel [D]
16-10 FRAME
Control Panel
Glove Compartment Removal
• Remove:
Control Panel (see Control Panel Removal)
Screws [A]
Left Glove Compartment [B]
Right Glove Compartment [C]
FRAME 16-11
Front Cargo Compartment
Front Cargo Hood Removal
• Remove:
Rear Snap Pins [A]
Mounting Pins [B]
Front Snap Pin [C] (Left side)
• Slide the front cargo hood [D] to the right and remove it.
• Remove:
Arm Assembly Bolts [A]
Arm Assembly [B]
Caps [C]
Stay [D]
• Remove:
Mounting Screws [A]
Bracket [B]
Front Cargo Compartment Removal

• Remove:
Front Cargo Hood (see Front Cargo Hood Removal)
Mounting Rivets [A]
Screws and Hooks [B]
Screws [C]
Front Cargo Compartment [D]
16-12 FRAME
Cargo Bed
Cargo Bed Removal
• Remove:
Hooks [A] (unlock, both sides)
• Remove:
Rear Fenders Mounting Screws [A]
Rear Fenders [B]
• Remove:
Tail/Brake Light Wires [A]
Tail/Brake Light Mounting Bolts [B]
Tail/Brake Light Assemblies [C]
• Remove:
Snap Pins [A]
Cargo Bed Mounting Pins [B]
Cargo Bed [C]
Cargo Bed Installation

• Grease:
Cargo Bed Mounting Pins
• Apply adhesive agent:
Cargo Bed Rubber Dampers (Bottom) [A]
Tail Gate Pivot Rubber Dampers (Left and Right)
FRAME 16-13
Cargo Bed
• When the cargo bed is disassembled, note the following

when installing the plates and the tail gate.
• Be sure there is the clearance [A] between the back end
of the carrier [B] and the bottom of the tail gate [C] (Left
and Right).
• Be 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
(Left and Right).
16-14 FRAME
Front and Rear Bars
Front Bar Removal
• Remove:
Front Bar Mounting Bolts [A]
Front Bar [B]
Front Bar Installation

• Tighten:
Torque - Front Bar Mounting Bolts (Lower): 98 N·m (10
kgf·m, 72 ft·lb)
Front Bar Mounting Bolts (Upper): 44 N·m (4.5
kgf·m, 33 ft·lb)
Rear Bar Removal

• Remove:
Rear Bar Mounting Bolts (Upper) [A]
• Remove:
Air Duct Clamp [A] (loosen) and Air Duct
Rear Bar Mounting Bolts [B]
• Remove:
Air Duct Clamp [A] (loosen) and Air Duct
Rear Bar Mounting Bolts [B]
Rear Bar [C]
Rear Bar Installation

• Tighten:
Torque - Front Bar Mounting Bolts (Upper): 44 N·m (4.5
kgf·m, 33 ft·lb)
Rear Bar Mounting Bolts and Nuts: 44 N·m (4.5
kgf·m, 33 ft·lb)
FRAME 16-15
Front and Rear Bars
Cargo Bed Latch Position Inspection
• Cargo bed latches [A] must rest securely on the cargo bed
hooks [B] without rattling.
If there is rattling or not snug enough, adjust the latch
positions.
Cargo Bed Latch Position Adjustment

• Loosen the mounting bolts [C].
• the ellipse bolt
Reposition the latch to the suitable place by sliding within
holes.
• Retighten the mounting bolts.
NOTE
○Adjustment must be made on both sides.
16-16 FRAME
Front Fender Assembly
Front Guard Removal
• Remove:
Front Guard Bolts [A]
Front Guard [B]
Front Cover Removal

• Remove:
Screws [A]
Guards [B]
• Remove:
Rivets [A]
Screws [B]
• Remove:
Rivets [A]
• Remove:
Screws [B]
• Remove thethefrontbands
Disconnect and the headlight connectors.
• cover [C].
FRAME 16-17
Front Fender Removal
• Remove:
Screws [A]
Guards [B]
• Remove:
Coolant Reserve Tank from Frame
Rivets [A]
• Remove:
Screws [A]
Plugs [B] and Screws
Screws and Nuts [C]
Front Fender [D]
Radiator Side Cover Removal

• Remove:
Screws [A]
Bolts [B]
Radiator Side Covers [C]
Radiator Side Cover Installation

• Apply adhesive agent:
Radiator Side Cover Trims [A]
16-18 FRAME
• When the guide [A] is removed from the flap [B], note the
following when installing.
○Do not pinch the guide skirt [C] on the flap [B] when in-
stalling the guide (Left and Right).
Radiator Side Cover Flap Removal

• Remove:
Radiator Side Cover (see Radiator Side Cover Removal)
Screw [A], Nut and Washer
Clamps [B]
Radiator Side Cover Flap [C]
Floor Center Panel Removal

• Remove:
Screws [A]
Seat Lower Cover [B]
• Remove:
Screws [A]
Bolts [B]
Floor Center Panel [C]
FRAME 16-19
Rear End Sub-frame
Rear End Sub-frame Removal
• Remove:
Transmission Case (see Transmission chapter)
Rear End Sub-frame Mounting Bolts [A] and Nuts
Rear End Sub-frame [B]
Rear End Sub-frame Installation

• Tighten:
Torque - Rear End Sub-frame Mounting Nuts: 44 N·m (4.5
kgf·m, 33 ft·lb)
ELECTRICAL SYSTEM 17-1
Electrical System
Table of Contents
Exploded View................................... 17-3 Starter Motor Disassembly........... 17-42
Wiring Diagram (KAF950-B1)............ 17-10 Starter Motor Assembly ............... 17-44
Wiring Diagram (KAF950-B2)............ 17-12 Carbon Brush Inspection ............. 17-45
Wiring Diagram (KAF950-B3, B6F) ... 17-14 Yoke Inspection............................ 17-45
Wiring Diagram (KAF950B7F)........... 17-16 Brush Plate Inspection ................. 17-46
Specifications .................................... 17-18 Pinion Gear Inspection................. 17-46
Special Tools and Sealant ................. 17-19 Electric Starter System (KAF950B6F
Parts Location.................................... 17-20 ∼)..................................................... 17-47
Precautions........................................ 17-22 Starter Motor Removal................. 17-47
Electrical Wiring................................. 17-24 Starter Motor Installation.............. 17-47
Wiring Inspection ......................... 17-24 Starter Motor Disassembly........... 17-47
Battery ............................................... 17-25 Starter Motor Assembly ............... 17-49
Battery Removal .......................... 17-25 Carbon Brush Inspection ............. 17-50
Battery Installation ....................... 17-25 Yoke Inspection............................ 17-51
Electrolyte Level Inspection Brush Plate Inspection ................. 17-51
(Conventional Type Battery)...... 17-27 Pinion Gear Inspection................. 17-51
Electrolyte Specific Gravity Electric Starter System ...................... 17-52
Inspection (Conventional Type Commutator Cleaning/Inspection. 17-52
Battery)...................................... 17-27 Armature Inspection..................... 17-52
Charging Condition Inspection Starter Switch Inspection ............. 17-52
(Conventional Type Battery)...... 17-27 Starter Circuit Relay Inspection ... 17-53
Initial Charging (Conventional Preheating System ............................ 17-55
Type Battery)............................. 17-28 Glow Plug Removal ..................... 17-55
Charging Condition Inspection Glow Plug Installation .................. 17-55
(Sealed Type Battery) ............... 17-30 Glow Plug Inspection ................... 17-55
Ordinary Charging........................ 17-31 Preheating Timer Inspection ........ 17-55
Battery Testing Chart Glow Plug Relay Inspection ......... 17-56
(Conventional Type Battery)...... 17-33 Glow Plug Relay Installation ........ 17-56
Alternator ........................................... 17-35 Fuel Cut Solenoid .............................. 17-58
Alternator Removal ...................... 17-35 Fuel Cut Solenoid ........................ 17-58
Alternator Installation ................... 17-35 Fuel Cut Solenoid Inspection ....... 17-58
17
Alternator Disassembly ................ 17-35 Radiator Fan...................................... 17-59
Alternator Assembly..................... 17-37 Radiator Fan Circuit Inspection.... 17-59
Alternator Operational Inspection 17-38 Radiator Fan Motor Inspection..... 17-59
Stator Coil Inspection................... 17-39 Radiator Fan Breaker Inspection
Rotor Coil Inspection.................... 17-39 (KAF950B7F) ............................ 17-59
Slip Ring Cleaning ....................... 17-39 Lighting System ................................. 17-62
Slip Ring Diameter ....................... 17-39 Headlight Beam Adjustment ........ 17-62
Carbon Brush Length................... 17-40 Headlight Bulb Replacement ....... 17-62
Rectifier Inspection ...................... 17-40 Tail/Brake Light Replacement ...... 17-63
Regulator Inspection .................... 17-40 Reverse Light Switch Installation
Alternator Ball Bearing Inspection 17-40 (Option) ..................................... 17-63
Electric Starter System (KAF950-B1 Switches ............................................ 17-65
∼ B3) ............................................... 17-42 Brake Light Switch Inspection...... 17-65
Starter Motor Removal................. 17-42 Radiator Fan Switch Inspection ... 17-65
Starter Motor Installation.............. 17-42
17-2 ELECTRICAL SYSTEM
Water Temperature Warning Light Fuse Removal.............................. 17-68

Switch Inspection ...................... 17-66 Fuse Installation........................... 17-68
Switch Inspection ......................... 17-67 Fuse Inspection............................ 17-68
Fuses................................................. 17-68
Exploded View
Dummy Page
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Alternator Adjusting Bracket Bolts 20 2.0 14
2 Alternator Mounting Bolt 39 4.0 29
3 Alternator Pulley Locknut 11 1.1 95 in·lb
4 Starter Motor Through Bolts 9.3 0.95 82 in·lb
5 Starter Motor End Cover Screws 1.5 0.15 13 in·lb
6 Starter Motor Mounting Bolts 39 4.0 29
7. KAF950B6F
SG: Apply grease.- Denso No. 50 grease or equivalent (Esso beacon 325)
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Connecting Plate Nuts 1.2 0.12 10 in·lb
2 Glow Plugs 17 1.7 12
3 Radiator Fan Switches 25 2.5 18
4 Water Temperature Warning Light Switch 27 2.8 20 L
5 Oil Pressure Switch 14 1.4 10 SS
6 Neutral Switch 15 1.5 11
7. Hour meter
8. Preheating timer
9. Glow plug relay
10. Starter circuit relay
11. Fuel cut solenoid connector
12. Light switch
13. Other than United States Model and KAF950-B1 ∼, B6F (United States Models)
14. KAF950B7F (United States Model)
G: Apply grease to O-rings.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
Exploded View
Exploded View
1. Horn switch contact
2. Steering gear assembly
3. Ground lead connection
4. Horn
5. Reverse light switch
6. Reverse light
Wiring Diagram (KAF950-B1)
Wiring Diagram (KAF950-B3, B6F)
Wiring Diagram (KAF950-B3, B6F)
Wiring Diagram (KAF950B7F)
Wiring Diagram (KAF950B7F)
Specifications

Battery
Capacity 12 V 52 Ah – – –
Voltage 12.6 V or more – – –
Conventional Type:
Electrolyte Level Between upper and lower level – – –
Specific Gravity 1.265 @20° (68°F) – – –
Alternator
Type Three-phase – – –
(built-in regulator/rectifier)
Fan Belt Deflection 9.5 ∼ 11.5 mm/10 kgf – – –
Output Voltage (25°C) 13.3 ∼ 14.8 V – – –
Output Amperage (No load) 10 A or less – – –
Output Amperage (Load) 20 A or more – – –
Stator Coil Resistance 0.2 Ω or less – – –
Rotor Coil Resistance 2.8 ∼ 3.0 Ω – – –
Slip Ring Diameter 14.4 mm (0.57 in.) 14.0 mm (0.55 in.)
Carbon Brush Length (Projected Portion) 10.5 mm (0.41 in.) 8.4 mm (0.33 in.)
Electric Starter System
Starter Motor:
Carbon Brush Length 13.5 mm (0.53 in.) 8.5 mm (0.33 in.)
Commutator Diameter 30 mm (1.18 in.) 29 mm (1.14 in.)
Preheating System
Glow Plug Resistance about 0.1 ∼ 5.0 Ω – – –
Switches
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°C – – –
(178 ∼ 185°F)
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
Water Temperature Warning Light
Switch Resistance:
Rising Temperature From OFF to ON at 112 ∼ 118°C – – –
(234 ∼ 244°F)
Falling Temperature From ON to OFF – – –
within 10°C (50°F) of
“ON” temperature
Socket Wrench, Hex 22: 1207F
57001-1236 Hand Tester:
57001-1394
Three Bond:
Parts Location
Hour Meter [A]
Main Switch [B]
Glow Plug Light [C]
Power Outlet Connector [D]
Oil Pressure Warning Indicator Light [E]
Coolant Temperature Warning Indicator Light [F]
Parking Brake Indicator Light [G]
Light Switch [A]

Speedometer [B]
Horn Button [C]
Ground Lead Terminal (Frame) [A]

Preheating Timer [B]
Parking Brake Light Switch [C]
Glow Plug Relay [D]
Battery [E]
Fuse Box [A]

Starter Circuit Relay [B]
Radiator Fan Switch [C] (Rear)
Radiator Fan [D] (Rear)
Starter Motor [A]

Alternator [B]
Glow Plugs [C]
Water Temperature Warning Light Switch [D]
Parts Location
Oil Pressure Switch [A]
Fuel Cut Solenoid Valve [B]
Neutral Switch [C]
Reverse Switch [D] (option)
Horn [A]
Radiator Fan Switch [B] (Front)
Radiator Fan [C] (Front)
Ground Lead Terminal (Engine) [A]

Starter Motor [B]
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○Do not reverse the battery lead connections. This will
burn out the diodes in the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The 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.
○To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the main switch is on, or while the engine is running.
○Because of the large amount of current, never keep the
main switch turned to the start position when the starter
motor will not turn over, or the current may burn out the
starter motor windings.
○Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
○Troubles 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.
○Make 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.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Color Codes:
BK Black G Green P Pink
BL Blue GY Gray PU Purple
BR Brown LB Light Blue R Red
CH Chocolate LG Light Green W White
DG Dark Green O Orange Y Yellow
○Electrical Connectors:
Connectors [A]
Precautions
Connectors [B]
Electrical Wiring
Wiring Inspection
• Visually
etc.
inspect the wiring for signs of burning, fraying,
If any wiring is poor, replace the damaged wiring.

•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.
•Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Measure the resistance between the ends of the leads.
If the resistance is not 0 Ω, the lead is defective. Replace
the lead or the wiring harness if necessary.
Battery
○In this model, two batteries are prepared.

Conventional Type Battery [A] (other than US model and
KAF950-B1 ∼, B6F US models)
The caps [B] can be removed.
Sealed Type Battery [A] (KAF950B7F US model)
Battery Removal
• first,
Disconnect the battery negative (−) cable and lead [A]
and then the positive cable and leads [B].
• Remove:
Battery Holder [C]
• out the battery [D].
Take
Battery Installation
• Check that the rubber dampers [A] on the battery case [B]
are properly in place.
• Install the O-ring [A] from the opposite end of the threads
[B] of the battery holder rod [C] to protect the O-ring.
NOTE
○Do not set the O-ring on the threads of the rod.
• Install:
Battery Holder Rod
Pipe
Battery
• Put the battery on the case so that the positive terminal

faces forward.
• Check that the rubber dampers [A] on the battery holder
[B] are properly in place.
Battery
• Install:
Battery Holder [A]
• Tighten:
Torque - Battery Holder Mounting Nut [B]: 17 N·m (1.7
kgf·m, 12 ft·lb)
[C] Pipe
[D] O-ring
[E] Battery Case
[F] Battery Holder Rod
• Connect the four leads on the positive lead connector [A]

as shown.
[B] Red
[C] Blue, White
[D] Black/White
[E] Red (Alternator Lead)
• Connect the positive (+) cable first, and then connect the
negative (–) cable and lead (Black and Black/Yellow).
• Put a light coat of grease on the terminals to prevent cor-
rosion.
• Install:
Positive Terminal Cover
• Connect
cable.
the positive (+) cable first and then the negative
• Apply grease around terminals to prevent corrosion.

Electrolyte Level Inspection (Conventional Type
Battery)
• Refer to the Electrical System in the Periodic Mainte-
nance chapter.
Electrolyte Specific Gravity Inspection (Conventional
Type Battery)
nance chapter.
Charging Condition Inspection (Conventional Type
Battery)
nance chapter.
Battery
Initial Charging (Conventional Type Battery)
WARNING
Keep the battery away from sparks and open flames
during charging, since the battery gives off an ex-
plosive gas mixture of hydrogen and oxygen. 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.
CAUTION
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°C (113°F) during charging, reduce the charging
rate to lower the temperature, and increase charg-
ing time proportionately.
• Remove:
Battery
Filler Caps (see Electrolyte Level Inspection)
WARNING
• Place the carton [A] on a flat surface as shown, pull the

tab back to edge of the carton.
• Pull out the hose [B] and cut off end of the hose.
Battery
• Fill each cell [A] until the electrolyte level rises to bottom
[B] of the split ring [C] of the vent well.
CAUTION
Do not fill into the split [D].
Do not overfill.
• After filling cells, wait five to ten minutes.

If necessary to bring electrolyte to proper level, add the
additional electrolyte.
WARNING
Neutralize any residue with baking soda.
Rinse empty package with large quantities of water.
Destroy empty package to prevent accidents!
• 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.)
Battery
Charging Condition Inspection (Sealed Type Battery)
Battery charging condition can be checked by measuring
battery terminal voltage.
• Remove the battery
CAUTION
Be sure to disconnect the negative (−) lead first.
• Measure the battery terminal voltage.

NOTE
○Measure with a digital voltmeter [A] which can be read
to one decimal place voltage.
If the reading is below the specified, refreshing charge is
required.
Battery Terminal Voltage
Standard: 12.6 V or more
If violent gassing or spewing occurs, reduce the charge

rate.
CAUTION
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.
• After charging, if the electrolyte level has fallen, refill the

battery with the electrolyte to upper level.
Battery
• Fit the filler caps [A] firmly.
Ordinary Charging
WARNING
Keep the battery away from sparks and open flames
during charging, since the battery gives off an ex-
plosive gas mixture of hydrogen and oxygen. 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.
CAUTION
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 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°C (113°F) during charging, reduce the charging
rate to lower the temperature, and increase charg-
ing time proportionately.
• Remove:
Battery (see Battery Removal)
NOTE
○Never attempt to charge a frozen battery.
○Allow it to warm up to room temperature before charg-
ing.
○Never leave a battery on a trickle longer than 48 hours.
Serious damage to the battery will occur.
Battery
(Conventional Type Battery)
• 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°C (60°F).
• Refer to the Battery Charging Time Table for the charging.
• Check the electrolyte level after charging.

If the electrolyte level is low add water only after initial
activation.
WARNING
• Turn the charger off or plug it, then disconnect it from the
battery.
If the battery condition indicates that it is not fully charged,
additional charging time is necessary.
(Sealed Type Battery)
• 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.
• Refer to the Battery Charging Time Table for the charging.

Battery Charging Time Table at 27°C (80°F)
Battery State of Charging Time to Full Charge
Voltage Charge 2 A 6 A 10 A
12.6 V 100% Full Charge
12.4 V 75% 405 min. 135 min. 81 min.
12.2 V 50% 810 min. 270 min. 162 min.
12.0 V 25% 1 215 min. 405 min. 243 min.
11.8 V 0% 1 620 min. 540 min. 324 min.
•○Determine battery condition after charging.

Determine the condition of the battery 30 minutes after
completion of the charge by measuring the terminal volt-
age according to the table below.
Criteria Judgement
12.6 V or higher Good
12.0 ∼ 12.6 V or lower Charge insufficient → Recharge
12.0 V or lower Unserviceable → Replace
Battery
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.
Battery
Battery Testing Chart
Alternator
Alternator Removal
• Remove:
Fan Belt Cover (see Cooling Fan Belt Inspection section
in Periodic Maintenance chapter)
Alternator Adjusting Bracket Bolt [A]
Alternator Mounting Bolt [B]
Alternator [C]
Alternator Installation
• Clean the alternator legs and alternator bracket where the
alternator is grounded.
•○Adjust the fan belt deflection.
Use a ruler, push the belt with 10 kg (22 lb) force.
Fan Belt Deflection
Standard: 9.5 ∼ 11.5 mm/10 kgf
• Tighten:
Torque - Alternator Adjusting Bracket Bolts: 20 N·m (2.0
kgf·m, 14 ft·lb)
ft·lb)
Alternator Disassembly
• Remove:
Terminal Nut [A]
Insulator [B]
End Cover Bolts [C]
End Cover [D]
• Remove:
Brush Holder [A]
Regulator [B]
Alternator
• Remove:
Rectifier Screws [A]
• Straighten the stator coil wires [A].

• Rectifier [B]
Remove:
• Use:
Socket Wrench [A]
Deep Socket Wrench [B]
Special Tool - Socket Wrench, Hex 22: 57001-1236
• Remove:
Pulley Locknut
Pulley [C]
• Remove:
Collar [A]
• Remove:
Housing Cover Mounting Bolts [A] and Nuts [B]
Alternator
• Remove:
Housing Cover [A]
Rotor [B]
Alternator Housing [C]
• Remove:
Bearing Holder [A]
Ball Bearing [B]
○To remove the ball bearing [A], use a suitable puller.
Alternator Assembly
• Press the bearing and bearing holder onto the rotor shaft.
• Install: the stator coil wires.
Straighten
• Housing Cover [A]
Housing Cover Mounting Bolts [B] and Nuts [C]
• Install:
Rectifier [A]
• Tightenthethestator
Bend coil wire ends [B] around the screw holes.
• rectifier screws.
Alternator
• Install:
Regulator
Brush Holder
End Cover
Insulator
Terminal Nut
• Install:
Collar
Pulley [A]
• Use:
Socket Wrench [B]
Deep Socket Wrench [C]
Special Tool - Socket Wrench, Hex 22: 57001-1236
• Tighten:
Torque - Alternator Pulley Locknut: 11 N·m (1.1 kgf·m, 95
in·lb)
Alternator Operational Inspection

• Check the battery condition (see Charging Condition In-
spection).
NOTE
○Always check the battery condition before condemning
the alternator. The battery must be fully charged in or-
der to conduct accurate alternator inspection.
• Check the wiring (see Wiring Inspection).

• Warm up the engine to bring the components up to their
normal operating temperatures.
• 15 A Fan Fuses
Remove:
• Connect the hand tester [A] (range DC 25 V) and ammeter

[B] (range DC 40 A, after the engine start) as shown.
Battery [C]
50 A Fuse [D]
Alternator [E]
Load [F]
• Measure the alternator output voltage and amperage at
2 000 rpm with the light switch turned OFF.
Alternator Output Voltage (25°C)
Standard: 13.3 ∼ 14.8 V
Alternator Output Amperage (no load)

Standard: 10 A or less
Alternator

• 15 A Fan Fuses
Install:
• Measure the alternator output voltage and amperage at

2 000 rpm with the light switch turned ON.
Alternator Output Voltage (25°C)
Standard: 13.3 ∼ 14.8 V
Alternator Output Amperage (load)

Standard: 20 A or more
If the readings are not within the specified range, check
the alternator.
Stator Coil Inspection
• Connect the hand tester (× 1 Ω range) between the coil
wires and read the tester.
If the tester does not read as specified, replace the alter-
nator frame.
Stator Coil Resistance: 0.2 Ω or less
• Using the highest hand tester range, measure the resis-

tance between the stator coil core and each of the coil
windings.
If there is any reading at all, the stator coil winding has a
short and the alternator housing must be replaced.
Rotor Coil Inspection
• Connect the hand tester (× 1 Ω range) between the slip
rings [A] and read the tester.
If the tester does not read as specified, replace the rotor
[B].
Rotor Coil Resistance: 2.8 ∼ 3.0 Ω
• Using the highest tester range, measure the resistance

between the rotor shaft and each of the slip rings.
If there is any reading at all, the rotor coil has a short and
must be replaced.
Slip Ring Cleaning
• Visually inspect the slip ring for dirt or pitting.
If necessary, smooth the slip ring with No. 300 ∼ No. 500
emery cloth.
Slip Ring Diameter
• Measure the diameter of the slip rings.
If the measurement is less than the service limit, replace
the rotor [A].
Slip Ring Diameter
Alternator
Carbon Brush Length
• 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)
Rectifier Inspection
• Set the hand tester to the 1 kΩ range.
• checkthethehand
Zero tester, and connect it to each terminal to
resistance in both directions.
○The 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
○The 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.
CAUTION
If a megger or a meter with a large-capacity battery
is used, the rectifier will be damaged.
Regulator Inspection
• Set the hand tester to the 1 kΩ range.
• in both the
Check resistance between F [A] and B [B] terminals
directions.
○The resistance should be low in one direction and more
than ten times as much in the other direction.
If the reading shows low or high in both directions, the
regulator [C] is defective and must be replaced.
Alternator Ball Bearing Inspection

CAUTION
Do not disassemble the alternator for bearing in-
spection since disassembling the alternator dam-
ages the bearings.
• Turn the alternator rotor shaft back and forth while check-
ing for play, roughness or binding of bearings.
If bearing play, roughness, or binding is found, disassem-
ble the alternator and replace the bearings.
Alternator
Alternator Circuit
1. Alternator
2. Stator Coil
3. Rotor
4. Rectifier
5. Regulator
6. Battery
7. 50 A Fuse
8. 30 A Fuse
9. Ignition Switch
10. Load
Electric Starter System (KAF950-B1 ∼ B3)
Starter Motor Removal
• Remove:
Starter Motor lead Connector [A]
Starter Motor lead [B]
Starter Motor Mounting Bolts [C]
Starter Motor [D]
Starter Motor Installation

• Clean the mating surface [A] of the starter motor and the
end plate where the starter motor is grounded.

• Install the starter motor and tighten the mounting bolts.
Torque - Starter Motor Mounting Bolts: 39 N·m (4.0 kgf·m,
29 ft·lb)
Starter Motor Disassembly

• Remove:
Magnetic Switch lead Nut [A]
Magnetic Switch lead [B]
• Remove:
Starter Motor Through Bolts [A]
Yoke [B]
• Remove:
End Cover Screws [A]
End Cover [B]
• Remove:
Armature [A]
Positive Brushes [B]
Brush Plate [C]
• Remove:
Drive End Cover Screws [A]
Drive End Cover [B]
• Remove:
Starter Clutch [A]
Idle Gear [B]
Steel Ball [C]
• Remove:
Retainer [A] and Rollers [B]
• Remove:
Return Spring [A]
Starter Motor Assembly

• Grease:
Grease - Denso No. 50 Grease or Equivalent (Esso Beacon
325)
Retainer and Rollers
Starter Clutch
Steel Ball
Return Spring
Armature Bearing
• Install the retainer [A] and rollers [B] on the drive end
cover shaft [C].
○Face the opening side [D] of the retainer to the drive end
cover.
• Install:
Starter Clutch [A] with Idle Gear [B]
• Install:
Steel Ball
Return Spring
Drive End Cover and Screws
• Install the positive brushes [A] on the brush plate [B] with
needle nose pliers.
• Install:
Armature [C]
○Pull the springs [D] and hold them with suitable plates [E]
as shown.
• Install:
End Cover
• Tighten:
Torque - Starter Motor End Cover Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Fit the projection [A] on the yoke [B] into the notch [C] in
the magnetic switch [D].
• Tighten:
Torque - Starter Motor Through Bolts: 9.3 N·m (0.95 kgf·m,
82 in·lb)
• Install
curely.
the magnetic switch lead and tighten the nut se-
Carbon Brush Inspection

• Measure the carbon brush length [A].
If the brush length is less than the service limit, replace
the brush assembly.
Carbon Brush Length
Yoke Inspection
• Measure the resistance between the carbon brush and
the wire terminal [A].
If there is not close to 0 Ω, the field coils have an open.
Replace the yoke.
the yoke body [B].
If there is any reading, the yoke has a short. Replace the
yoke.
Brush Plate Inspection
the brush plate [A].
If there is not close to 0 Ω, the brush plate has an open.
Replace the brush plate.
• Measure the resistance between the brush plate and the
(+) brush holder [B].
If there is any reading, the brush plate has a short. Re-
place the brush plate.
Pinion Gear Inspection

• Turn the pinion gear by hand. It should turn clockwise
freely [A], but should not turn freely counterclockwise [B].
If the pinion gear does not operate as it should or if there
is any worn or damaged part, replace it.
Electric Starter System (KAF950B6F ∼)
Starter Motor Removal
• Remove:
Starter Motor Lead Connector [A]
Starter Motor Lead [B]
Starter Motor Mounting Bolts [C]
Starter Motor [D]
Starter Motor Installation

• Clean the mating surface [A] of the starter motor and the
end plate where the starter motor is grounded.

• Install the starter motor and tighten the mounting bolts.
Torque - Starter Motor Mounting Bolts: 39 N·m (4.0 kgf·m,
29 ft·lb)
Starter Motor Disassembly

• Remove:
Field Coil Cable Nut [A]
Field Coil Cable [B]
• Remove:
Starter Motor Through Bolts [A]
Yoke [B]
• Remove:
End Cover Screws [A] and O-rings
End Cover [B]
• Remove:
Armature [A]
Positive Brushes [B]
Brush Plate [C]
• Remove:
Drive End Cover Screws [A]
Drive End Cover [B]
• Remove:
Starter Clutch [A]
Idle Gear [B]
Steel Ball [C]
• Remove:
Retainer [A] and Rollers [B]
• Remove:
Return Spring [A]
Starter Motor Assembly

• Grease:
Grease - Denso No. 50 Grease or Equivalent (Esso Beacon
325)
Retainer and Rollers
Starter Clutch
Steel Ball
Return Spring
Armature Bearing
• Install the retainer [A] and rollers [B] on the drive end
cover shaft [C].
○Face the opening side [D] of the retainer to the magnetic
switch assy.
• Install:
Starter Clutch [A] with Idle Gear [B]
• Install:
Steel Ball
Return Spring
Drive End Cover and Screws
• Install the positive brushes [A] on the brush plate [B] with
needle nose pliers.
○Pull the springs [C] and brashes, and hold the brushes
with the springs.
• Install:
Armature
• Install:
End Cover [A]
End Cover Screws [B] and O-rings
• Tighten:
Torque - Starter Motor End Cover Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Install the yoke [A] on the magnetic switch [B]

• Tighten:
Torque - Starter Motor Through Bolts: 9.3 N·m (0.95 kgf·m,
82 in·lb)
• Install the field coil cable and tighten the nut securely.
Carbon Brush Inspection
• Measure the carbon brush length [A].
If the brush length is less than the service limit, replace
the brush assembly.
Carbon Brush Length
Yoke Inspection
the wire terminal [A].
If there is not close to 0 Ω, the field coils have an open.
Replace the yoke.
the yoke body [B].
If there is any reading, the yoke has a short. Replace the
yoke.
Brush Plate Inspection

the brush plate [A].
If there is not close to 0 Ω, the brush plate has an open.
Replace the brush plate.
• Measure the resistance between the brush plate and the
(+) brush holder [B].
If there is any reading, the brush plate has a short. Re-
place the brush plate.
Pinion Gear Inspection

• Turn the pinion gear by hand. It should turn clockwise
freely [A], but should not turn freely counterclockwise [B].
If the pinion gear does not operate as it should or if there
is any worn or damaged part, replace it.
Commutator Cleaning/Inspection
• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
• 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.
Commutator Diameter
Armature Inspection
• resistance
Using the × 1 Ω range of the hand tester, measure the
between any two commutator segments [A].
If there is a high resistance or no reading (∞) between
any two segments, a winding is open. Replace the starter
motor.
• Using the highest range of the hand tester, measure the
resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short.
Replace the starter motor.
NOTE
○Even 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.
Starter Switch Inspection
•○Connect a 12 V battery to the starter switch [A] as shown.
Connect the battery negative (–) lead [B] first and then the
positive lead to the terminal in the connector [C].
If the switch does not work 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
• Remove:
Starter Circuit Relay [A]
Starter Circuit Relay Connector [B]
• Connect the hand tester [A] and 12 V battery [B] to the

starter circuit relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Hand Tester Range: × 1 Ω
Criteria: When battery is connected ⇒ 0Ω
When battery is disconnected ⇒ ∞Ω
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
Electric Starter Circuit
1. Starter Motor
2. Starter Circuit Relay
3. Neutral Switch
4. Battery
5. 30 A Fuse
6. 30 A Fuse
7. Ignition Switch
Preheating System
Glow Plug Removal
• Remove:
Caps [A]
• Remove:
Connecting Plate Nuts [A]
Connecting Plate [B]
Glow Plug Leads [C]
Glow Plugs [D]
Glow Plug Installation

• Tighten:
Torque - Glow Plugs: 17 N·m (1.7 kgf·m, 12 ft·lb)
Connecting Plate Nuts: 1.2 N·m (0.12 kgf·m, 10
in·lb)
Glow Plug Inspection

• Using the × 1 Ω range of the hand tester, measure the
resistance between the terminal [A] and the housing [B]
of the glow plug.
If the tester does not read as specified, replace the glow
plug.
Glow Plug Resistance: about 0.1 ∼ 5.0 Ω
NOTE
○Be careful not to apply the battery voltage to the glow
plug directly.
○Be careful not to scratch the heater section [C].
Preheating Timer Inspection
• Check that the ignition switch is turned off, and connect
the hand tester [A] to the preheating timer [B] as follows:
Hand Tester Range: DC 25 V
Hand Tester (+) Lead → Terminal (6) (Black)
Hand Tester (–) Lead → Ground
• When the ignition switch is turned ON, the reading should
show less than 1.8 V during 5 seconds.
If the preheating timer does not work, replace the timer.
Preheating System
Glow Plug Relay Inspection
• Remove:
Mounting Bolt [A] and Nut
Glow Plug Relay [B]
Glow Plug Relay Lead Connectors [C]
• Connect the hand tester [A] and 12 V battery [B] to the

glow plug relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Hand Tester Range: × 1 Ω
Criteria: When battery is connected ⇒ 0Ω
When battery is disconnected ⇒ ∞Ω
Relay Coil Terminals [85] and [86]
Relay Switch Terminals [30] and [87]
Glow Plug Relay Installation

• Connect
lows:
the leads to the glow plug relay terminals as fol-
Black Lead (Tag No. 85) → to Terminal No. 85 [A]

Brown Lead (Tag No.
→ to Terminal No. 86 [B]
86)
Black/White Lead (Tag
→ to Terminal No. 87 [C]
No. 87)
Black/White Lead (Tag
→ to Terminal No. 30 [D]
No. 30)
Preheating System
Preheating System Circuit
1. Neutral Switch
2. Starter Circuit Relay
3. Preheating Timer
4. Glow Plug Relay
5. Ignition Switch
6. 5 A Fuse
7. 30 A Fuse
8. 30 A Fuse
9. Battery
10. Glow Plug Light
11. Glow Plugs
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 flows 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
• When the main switch is turned ON, check that the fuel
cut solenoid makes a clicking sound (operating sound).
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
1. Ignition Switch
2. Battery
3. 30 A Fuse
4. 5 A Fuse
5. Fuel Injection Pump
6. Fuel Cut Solenoid
Radiator Fan
Radiator Fan Circuit Inspection
• Remove:
Front Cargo Hood (for Front Radiator Fan, see Frame
chapter)
Floor Center Panel (for Rear Radiator Fan, see Frame
chapter)
• Disconnect the leads from the radiator fan switches.
• Using an auxiliary lead [A], connect the front radiator fan
switch leads.
• Using an auxiliary lead [B], connect the rear radiator fan
switch leads.
If the radiator fan rotates, inspect the radiator fan switch.
If the radiator fan does not rotate, inspect the following.
Wires and Connectors
Radiator Fan Fuse
Radiator Fan Motor
Radiator Fan Motor Inspection

• Disconnect the front fan motor leads [A] from the harness.
• Using two auxiliary
Disconnect the rear fan motor leads [B] from the harness.
• motor. leads, supply battery power to the fan
If the fan does not rotate at this time, the fan motor is
defective and must be replaced.
Radiator Fan Motor Leads
BL : Battery (+)
BK : Battery (–)
Radiator Fan Breaker Inspection (KAF950B7F)

• Remove:
Radiator Fan Breakers [A]
Radiator Fan
• Inspect the breaker for operation.

• 12 V Battery [A]
Connect:
0.6 Ω Resistance [B]

Radiator Fan Breaker [C]
Switch [D]
If the circuit in the breaker will not open within 60 seconds,
replace the breaker.
Radiator Fan Circuit (KAF950-B1 ∼, B6F)
1. Front Radiator Fan Switch

2. Front Radiator Fan
3. Rear Radiator Fan Switch
4. Rear Radiator Fan
5. 20 A Fuse
6. 20 A Fuse
7. Battery
Radiator Fan
Radiator Fan Circuit (KAF950B7F)
1. Front Radiator Fan Switch

2. Front Radiator Fan
3. Radiator Fan Breaker (Front)
4. Radiator Fan Breaker (Rear)
5. 20 A Fuse
6. 20 A Fuse
7. Rear Radiator Fan Switch
8. Rear Radiator Fan
9. Battery
Lighting System
Headlight Beam Adjustment
• Turn the adjusting screw [A] on each headlight rim in or
out to adjust the headlight vertically.
Headlight Bulb Replacement

• Remove:
Front Cargo Bed Compartment (see Frame chapter)
Dust Cover [A]
• Turn the bulb holder [B] counterclockwise and remove it.
• Remove:
Headlight Bulb [A]
• Insert the new bulb [A] by aligning the tang [B] with the
notch [C] in the headlight unit.
• Insert the bulb holder [A] by aligning the tangs [B] with the
notches [C] in the headlight unit.
• Push the holder and turn it clockwise. It should lock in the
position.
• Fit the dust cover completely.
Lighting System
Tail/Brake Light Replacement
•○Remove the lock pin type bulb [A].
Remove the tail/brake light lens.
○Push the bulb in, turn it counterclockwise, and pull it out
of the socket.
CAUTION
Do not use bulbs rated for greater wattage than the
specified value.
○Be careful not to overtighten the lens mounting screws.
Reverse Light Switch Installation (Option)
• Put the transmission shift lever in the REVERSE position.
• shift lever
Install the reverse light switch bracket [A] on the reverse
so that the switch rod [B] contacts the boss [C]
and the clearance is 1 ∼ 2 mm (0.04 ∼ 0.08 in.) [E].
• Tighten the shift shaft lever clamp bolt [D] securely.
Lighting System
Lighting System Circuit
1. Speedometer Illumination 9. Parking Brake Indicator Light

2. Headlights 10. Water Temperature Warning
3. Tail/Brake Lights Indicator Light
4. Light Switch Indicator Light 11. Battery
5. Light Switch 12. 30 A Fuse
6. Brake Light Switch 13. Ignition Switch
7. Water Temperature Warning Light Switch 14. Reverse Light Switch (Option)
8. Parking Brake Light Switch 15. Reverse Light (Option)
Switches
Brake Light Switch Inspection
• Refer to Brake Light Switch Inspection in the Periodic
Radiator Fan Switch Inspection
• Remove:
Radiator Fan Switch (see Cooling System chapter)
• the temperature
Suspend the fan switch [A] in a container of coolant so that
sensing projection and threaded portion
are submerged.
• Suspend an accurate thermometer [B] in the coolant, so
that the sensitive portions [C] are located in almost the
same depth.
NOTE
○The switch and thermometer must not touch the con-
tainer sides or bottom.
• Place the container over a source of heat and gradu-

ally raise the temperature of the coolant while stirring the
coolant gently.
• Using the hand tester, measure the internal resistance
of the switch across the terminals at the temperatures
shown in the table.
If the hand tester does not show the specified values, re-
place the switch.
Radiator Fan Switch Function and 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)
• Repeat the above steps for the other fan switch.

Switches
Water Temperature Warning Light Switch Inspection
• Remove:
Coolant Temperature Warning Light Switch (see Cooling
System chapter)
• Suspend the switch [A] in a container of coolant so that
the temperature sensing projection and threaded portion
are submerged.
• Suspend an accurate thermometer [B] in the coolant, so
that the sensitive portions [C] are located in almost in the
same depth.
NOTE
○The switch and thermometer must not touch the con-
tainer sides or bottom.
• Place the container over a source of heat and gradu-

ally raise the temperature of the coolant while stirring the
coolant gently.
• Using the hand tester, measure the internal resistance
of the switch across the connector and the body at the
temperatures shown in the table.
If the hand tester does not show the specified values, re-
place the switch.
Water Temperature Warning Light Switch Function and
Resistance
○ Rising temperature:
From OFF to ON at 112 ∼ 118°C (234 ∼ 244°F)
○Falling temperature:
From ON to OFF within 10°C (50°F)
of "ON" temperature
Switches
Switch Inspection
• Using a hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
○For the ignition switch, light switch, brake light switch,
parking brake light switch, and neutral switch, refer to ta-
bles in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Horn Switch Connection
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.

Reverse Light Switch Connection (Option)
Fuses
Fuse Removal
• Unlock the hook to lift up the lid [A].
• nose pliers.
Pull the fuses [B] straight out of the fuse box with a needle
[C] 50 A Fuse
Fuse Installation
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.
• Install the fuse box fuses on the original position as spec-
ified on the lid.
Fuse Inspection
• Remove the fuse.
• If it is blownfuse
Inspect the element.
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 components for
a short circuit.
Housing [A] Terminals [C]
Fuse Element [B] Blown Element [D]
CAUTION
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
Troubleshooting Guide ........................................................................................................... 18-2
Cable, Wires, and Hose Routing ............................................................................................ 18-6
18
18-2 APPENDIX
NOTE Fuel tank air vent obstructed
○This is not an exhaustive list, giving every Fuel injection pump trouble
possible cause for each problem listed. It Compression low:
is meant simply as a rough guide to assist Fuel injection nozzle loose
the troubleshooting for some of the more Glow plug loose
common difficulties. Cylinder head not sufficiently tightened
down
No valve clearance
Engine Doesn’t Start, Starting Difficulty:
Cylinder, piston worn
Starter motor not rotating:
Piston ring bad (worn, weak, broken, or
Neutral switch trouble
sticking)
Starter motor trouble
Piston ring/land clearance excessive
Battery voltage low
Cylinder head warped
Relays not contacting or operating
Cylinder head gasket damaged
Wiring open or shorted
Valve spring broken or weak
Main switch trouble
Valve not seating properly (valve bent,
Fuse blown
worn, or carbon accumulation on the
Starter motor rotating but engine doesn’t
seating surface)
turn over:
Other:
Starter motor trouble
Engine oil viscosity too high
Pinion or ring gear worn
Front final gear case oil viscosity too high
Engine won’t turn over:
Drive train trouble
Valve seizure
Brake dragging
Rocker arm seizure
Poor Running or No Power at High Speed:
Cylinder, piston seizure
Fuel/air mixture incorrect:
Crankshaft seizure
Air cleaner clogged, poorly sealed, or miss-
Connecting rod small end seizure
ing
Connecting rod big end seizure
Fuel tank air vent obstructed
Camshaft seizure
Fuel line clogged
No fuel flow:
Fuel injection pump trouble
Fuel tank air vent obstructed
Compression low:
Fuel injection pump trouble
Fuel Injection nozzle loose
Fuel filter clogged
Glow plug loose
Compression Low:
Cylinder head not sufficiently tightened
Fuel injection nozzle loose
down
Glow plug loose
No valve clearance
Cylinder head not sufficiently tightened
down
Piston ring bad (worn, weak, broken, or
No valve clearance
sticking)
Piston ring/groove clearance excessive
Piston rings bad (worn, weak, broken, or
sticking)
Piston ring/land clearance excessive
seating surface.)
Knocking:
Carbon built up in combustion chamber
seating surface)
Fuel poor quality or incorrect
Poor Running at Low Speed:
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or miss-
ing
APPENDIX 18-3
Miscellaneous: Driven pulley spring broken or weak
Brake dragging Converter engagement speed too low:
Overheating Drive pulley spring broken or weak
Engine oil level too high Converter engagement speed too high:
Engine oil viscosity too high Belt drive or worn
Front final gear case oil viscosity too high Drive or driven pulley sheave dirty or worn
Drive train trouble Drive pulley weight doesn’t move smoothly
Overheating: Drive pulley movable sheave doesn’t move
Fuel/air mixture incorrect: smoothly
Air cleaner clogged, poorly sealed, or miss- Drive or driven pulley movable sheave bush
ing worn
Compression high: Drive pulley weight or roller worn
Carbon built up in combustion chamber Shifting too quickly:
Engine load faulty: Drive pulley spring weak
Engine oil level too high Driven pulley spring weak or incorrectly in-
Engine oil viscosity too high stalled (too loose)
Drive train trouble Shifting too slowly:
Brake dragging Belt dirty or worn
Converter and/or belt excessive heating: Drive or driven pulley sheave dirty or worn
Belt dirty or worn Drive pulley weight doesn’t move smoothly
Drive or driven pulley sheave dirty or worn Drive pulley movable sheave doesn’t move
Driven pulley spring broken or weak smoothly
Drive pulley spring broken or weak Driven pulley spring incorrect installed (too
Idle speed too high tight)
Converter fan damaged Driven pulley movable sheave doesn’t
Lubrication inadequate: move smoothly
Engine oil level too low Gear Shifting Faulty:
Engine oil poor quality or incorrect Doesn’t go into gear:
Front final gear case overheating: Shift arm bent or seized
Insufficient oil Gear stuck on the shaft
Bevel gears maladjusted Shift cable maladjusted
LSD clutches maladjustment Shift cable lubrication inadequate
Coolant incorrect: Shift cable damaged
Coolant level too low Jumps out of gear:
Coolant deteriorated Shifter groove worn
Thick coolant Gear dogs worn
Cooling system component incorrect: Shift arm positioning bolt spring weak or
Radiator clogged broken
Thermostat trouble Shift block worn
Pressure relief valve cap trouble Transmission shaft, and/or gear splines
Radiator fan switch trouble worn
Fan motor broken Shift cable maladjusted
Fan blade damaged Overshifts:
Water pump not turning Shift arm positioning bolt spring weak or
Water pump impeller damaged broken
Over Cooling Shift cable maladjusted
Radiator fan switch trouble Abnormal Engine Noise:
Thermostat trouble Knocking:
Converter Operation Faulty: Carbon built up in combustion chamber
Belt slipping: Fuel poor quality or incorrect
Belt dirty, or worn Fuel injection nozzle incorrect
Drive or driven pulley sheave dirty or worn Overheating
18-4 APPENDIX
Piston Slap: Brake noise:
Cylinder/piston clearance excessive Brake linings overworn or worn unevenly
Cylinder, piston worn Drum worn unevenly or scored
Connecting rod bent Brake spring(s) weak or broken
Piston pin, piston holes worn Foreign matter in hub
Valve noise: Brake not properly adjusted
Valve clearance incorrect Other noise:
Valve spring broken or weak Bracket, nuts, bolt, etc. not properly
Camshaft bearing worn mounted or tightened
Rocker arm push rod runout excessive Exhaust Smokes Excessively:
Other noise: White smoke:
Connecting rod small end clearance exces- Piston oil ring worn
sive Cylinder worn
Connecting rod big end clearance exces- Valve oil seal damaged
sive Valve guide worn
Piston ring worn, broken, or stuck Engine oil level too high
Piston seizure or damaged Black Smoke:
Cylinder head gasket leaking Air cleaner clogged
Exhaust pipe leaking at cylinder head con- Brown smoke:
nection Air cleaner poorly sealed or missing
Crankshaft runout excessive Handling and/or Stability Unsatisfactory
Engine mounts loose Steering wheel hard to turn:
Crankshaft bearing worn Steering shaft bearing damaged
Cooling fan belt loose Steering shaft lubrication inadequate
Abnormal Drive Train Noise: Steering shaft bent
Converter noise: Steering gear assembly damaged
Belt worn Tire air pressure too low
Drive or driven pulley sheave worn LSD clutch maladjusted
Drive or driven pulley movable sheave bush Noise when turning:
worn Damaged side gear or pinion (Front final
Drive or driven pulley mount loose gear case)
Driven pulley shoe worn Worn clutch friction plate (Front final gear
Drive pulley weight or roller side washer case)
worn Worn clutch spring (Front final gear case)
Drive pulley weight or roller worn Steering wheel shakes or excessively
Transmission noise: vibrates:
Bearings worn Tire(s) worn
Transmission gears worn or chipped Suspension arm bushing worn
Metal chips jammed in gear teeth Tie-rod joint worn
Transmission oil insufficient Wheel rim warped
Final drive noise: Axle shaft bearing worn
Bearing worn Steering wheel mount loose
Gears worn or chipped Steering bolt or nut loose
Metal chips jammed in gear teeth Steering wheel pulls to one side:
Insufficient lubricant Frame bent
Bevel gears maladjusted Wheel misalignment
Worn LSD clutch friction plate Suspension arm bent or twisted
Worn LSD clutch spring Steering shaft bent
Universal joint damaged Steering gear assembly damaged
Abnormal Frame Noise: Front or rear tire air pressure unbalanced
Shock absorber noise: Shock absorber unbalanced
Shock absorber damaged
APPENDIX 18-5
Shock absorption unsatisfactory: Drum worn unevenly or scored
(Too hard) Oil, grease on lining and drum
Tire air pressure too high Dirt, water between lining and drum
Shock absorber damaged Overheated brakes
(Too soft) Battery Discharged:
Shock absorber oil leaking Battery faulty
Shock absorber spring weak Battery leads making poor contact
Tire air pressure too low Load excessive (e.g., bulb of excessive
Brake Doesn’t Hold wattage)
Air in the brake line Ignition switch trouble
Brake fluid leak Alternator trouble
Brake fluid deteriorated Wiring faulty
Primary or secondary cup trouble Battery Overcharged:
Master or wheel cylinder scratched inside Alternator trouble
Brake not properly adjusted Battery trouble
Linings overworn or worn unevenly
18-6 APPENDIX
Cable, Wires, and Hose Routing
1. Hi/Low Shift Cable 10. Brake Pipe

2. Transmission Shift Cable 11. Brake Hose
3. Throttle Cable 12. Clamp
4. Differential Shift Cable 13. Band
5. 2WD/4WD Shift Cable 14. Install the washer between the clamp
6. Parking Brake Cable and hook.
7. Parking Brake Cable (Left) 15. Leaf Springs
8. Parking Brake Cable (Right) 16. 50 mm (1.97 in.)
9. Main Harness
APPENDIX 18-7
1. Differential Shift Cable 6. Clamp

2. 2WD/4WD Shift Cable 7. To Engine
3. Hi/Low Shift Cable 8. Nut
4. Transmission Shift Cable 9. Torque Converter Case
5. Throttle Cable 10. Torque Converter Inner Cover
18-8 APPENDIX
1. Speedometer Cable
2. Clamp the speedometer cable with other cables, harness and brake pipe.
3. Clamp the speedometer cable with other cables.
4. Clamp the speedometer cable with the parking brake cable.
5. Band
APPENDIX 18-9
1. Brake Master Cylinder

2. Keep the hose away from the steering intermediate shaft.
3. Install the clamp in this direction.
4. Brake Hose (Left)
5. Brake Hose (Right)
6. Clamp the right brake hose with the harness.
18-10 APPENDIX
1. Breather Tube
2. Brake Hose
3. Coolant Reservoir Tank
4. Band
5. Clamp
6. Brake Pipe
APPENDIX 18-11
1. Right Brake Drum 7. Left Bracket

2. Right Bracket 8. Screw
3. Breather Tube 9. Clamp
4. Brake Pipe 10. Band
5. Brake Cable 11. Brake Hose
6. Left Brake Drum 12. Parking Brake Cable
18-12 APPENDIX
1. Right Headlight Lead 8. Oil Pressure Warning 15. Horn Button Lead
2. Horn Lead Indicator Light Lead 16. Optional Parts Lead
3. Radiator Fan Switch 9. Accessory Terminal Lead 17. Light Switch Lead
Lead 10. Coolant Temperature 18. Speedometer
4. Radiator Fan Lead Warning/Parking Brake Illumination
5. Band Indicator Light Wires 19. Main Harness
6. Ground Lead 11. Glow Plug Light 20. White Tape
(Steering Gear 12. Clamp 21. Brake Pipe
Assembly) 13. Main Switch Lead
7. Left Headlight Lead 14. Hour Meter Lead
APPENDIX 18-13
1. Altenator Lead 8. Battery (–) Cable

2. Band 9. Battery (+) Cable
3. Clamp 10. Main Harness
4. Neutral Switch Lead 11. Run the battery leads on the rubber.
5. Oil Pressure Switch Lead 12. Rubber
6. Parking Brake Light Switch 13. Brake Pipe (Rear-Left Side)
7. Trim
18-14 APPENDIX
1. Speedometer 6. Fix the ground lead 11. 2WD/4WD Shift Cable

Cable: Run the terminal to the steering 12. Transmission Shift Cable
speedometer cable gear assembly. 13. Brake Pipe
to the left of 7. Front Gear Case 14. Throttle Cable
the brake pipe. Vent Hose 15. Differential Shift Cable
2. Main Harness 8. Horn Lead 16. Brake Light Switch Lead
3. Radiator Fan Lead 9. Radiator Fan Switch 17. Radiator Fan Vent Hose
4. Clamp Lead
5. Band 10. Hi/Low Shift Cable
APPENDIX 18-15
1. Coolant Temperature 7. Speedometer Illumination (Lead)

Warning/Parking 8. Horn Button Lead
Brake Indicator Lights 9. Speedometer Cable
2. Band 10. Hour Meter (Lead)
3. Right Headlight Lead 11. Ignition Switch (Lead)
4. Left Headlight Lead 12. Glow Plug Light (Lead)
5. Main Harness 13. Accessory Terminals
6. Light Switch (Lead) 14. Oil Pressure Warning Indicator Light
18-16 APPENDIX
1. Main Harness 8. Brake Light Switch Lead 17. 300 mm (11.81 in.)
2. Speedometer Cable 9. Clamp 18. 80 mm (3.15 in.)
3. Front Gear Case 10. Radiator Fan Vent Hose 19. To Glow Plug Light
Vent Hose 11. To Main Switch 20. To Hour Meter
4. Horn Lead 12. To Right Headlight 21. To Horn Button
5. Radiator Fan Switch 13. To Left Headlight 22. To Speedometer
Lead 14. 110 mm (4.33 in.) Illumination
6. Radiator Fan 15. 170 mm (6.69 in.)
7. Band 16. 140 mm (5.51 in.)
APPENDIX 18-17
1. Left Headlight
2. Right Headlight
3. Clamp the tubes covered the headlight leads. Do not clamp on the leads or connectors.
4. Main Harness
5. Frame Ground Terminal
6. Preheating Timer
7. Glow Plug Relay
18-18 APPENDIX
1. Alternator Lead 10. Parking Brake 15. To Engine Ground

2. Main Harness Light Switch Lead (Black Lead)
3. Fuse Assembly 11. Trim 16. Rear Frame
4. Holder 12. Black Tape 17. Battery
5. Clamp 13. Put the lead connectors 18. Pay attention to the
6. Battery (+) Cable on the pipe as shown directions of leads.
7. Battery (–) Cable 14. To Starter Motor 19. Ground Lead (Engine)
8. Starter Circuit Relay (Red Lead) 20. Radiator Fan Breakers
9. Band
APPENDIX 18-19
1. Oil Pressure Switch Lead 8. To Neutral Switch

2. Injection Pump Lead 9. 80 mm (3.15 in.)
3. To Alternator (Red Lead) 10. Clamp
4. To Alternator 11. Accessory Terminals
5. To Starter Motor 12. Neutral Switch Terminal
6. Reverse Switch (Option) 13. Air Duct
7. Band 14. Water Pipe
18-20 APPENDIX
1. Horn Button
2. Horn Switch Contact
3. Ground Lead
4. to Main Harness
5. Band
APPENDIX 18-21
1. Air Intake (for Engine) 8. Converter

2. Air Cleaner (for Engine) 9. Duct
3. Air Filter Restriction Gauge 10. Tighten the clamp from behind.
4. Air Intake Manifold 11. Clamp
5. Muffler 12. Clamp shall not be installed in this area
6. Air Intake (for Converter) (“B” shall not enter in this area).
7. Air Cleaner (for Converter)
18-22 APPENDIX
1. Fuel Tank 5. Fuel Injection Pump

2. Fuel Supply Pipe 6. Fuel Injection Nozzle
3. Fuel Return Pipe 7. Band
4. Fuel Filter
APPENDIX 18-23
1. Front Radiator 6. Front Radiator Cap 11. Rear Radiator Cap

2. Fan Assembly 7. Run the reservoir tank 12. Rear Radiator
3. Install the radiator hoses hose under the frame 13. Rear Radiator
so that their white marks pipe Fan Switch
face upward. 8. Coolant Reservoir Tank
4. Clamp 9. Run the overflow hose
5. Front Radiator through the bracket hole.
Fan Switch 10. Air Bleeder Bolt
18-24 APPENDIX
KAF950-B2 ∼, B6F ∼
1. Diff Lock Cable

2. Cable Bracket
3. 100 mm (3.9 in.)
4. Cable Clamp
5. 2WD/4WD Shift Cable
MODEL APPLICATION
Year Model Beginning Frame No.
2003 KAF950-B1 JK1AFDB1□3B500001
JK1AFDB1□4B00000 or
2004 KAF950-B2
JK1AF950BBB00000
2005 KAF950-B3
JK1AF950BB601201
2006 KAF950B6F
JK1AF950BBB602651
2007 KAF950B7F
JKAF950BBB602881
□:This digit in the frame number changes from one machine to another.
Part No.99924-1306-05 Printed in Japan

Mule 3010 Diesel (2003-2007)

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MULE 3010

This quick reference guide will assist

Read OWNER’S MANUAL before operating.

KAF950-B1 Right Side View

Items KAF950-B1 KAF950-B2 ∼, B6F ∼

Open 10° BTDC

Items KAF950-B1 KAF950-B2 ∼, B6F ∼

Items KAF950-B1 KAF950-B2 ∼, B6F ∼

Units of Force Units of Power

Periodic Maintenance Chart .............. 2-2 Transmission .................................. 2-27

Fuel hose - replace 4 years 2-13

Cooling fan belt - inspect • 2-19

Converter drive belt - inspect* • 2-23

Converter drive belt deflection

Converter driven pulley shoe

Engine oil - change* 1 year • • 2-26

•: Clean, adjust, lubricate, torque, or replace parts as necessary.

•: Clean, adjust, lubricate, torque, or replace parts as necessary.

L: Apply a non-permanent locking agent to the threads.

Basic Torque for General Fasteners of Frame Parts

Item Standard Service Limit

Item Standard Service Limit

Rotor Puller, M16/M18/M20/M22 × 1.5: Brake Drum Holder:

Brake Drum Remover: Brake Drum Remover Nuts:

• Tilt up the cargo bed.

• Slide the adjuster [B] until the proper amount of throttle

• Start the engine and warm it up thoroughly.

•○Bleed the air from the fuel filter.

○Wipe off any spilled fuel.

• Tilt up the cargo hood.

• Tilt up the seat.

• Tighten the drain plugs.

Front Radiator Cap [A] Reservoir Tank Cap [C]

Water and Coolant Mixture Ratio (Recommended)

•○Bleed the air from the cooling system as follows.

• Install the reservoir tank cap.

Radiator Hose and Connection Inspection

• Remove the propeller shaft bearing housing mounting

• Tilt up the cargo bed.

Fan Cover Bolts (four bolts)

Torque - Fan Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•○Check the fan belt deflection.

• Loosen the alternator adjusting bracket bolt [A] and alter-

• Turn the crankshaft pulley [A] clockwise so that the timing

• Using a thickness gauge [A], measure the valve clearance

○When positioning #1 piston TDC at the compression

○Turn the crankshaft pulley 360° clockwise.

Valve Clearance Adjustment

• Remove the drain plug [A] from the muffler [B].

• Stop the engine.

• Clean the foam element in a bath of a high flash-point

Converter Drive Belt Inspection

• Check the belt for wear, cracks, breaks or peeling.

If the belt deflection is more than 36 mm (1.42 in.), remove

• With the transmission in neutral, rotate the driven pulley

If the ramps [A] or the wear shoes [B] are damaged or

Oil Filter Installation

• Tilt up the front cargo hood.

Front Cargo Compartment [B]