Professional Documents
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Mule 4010-4000 4x4 en Ingles
Mule 4010-4000 4x4 en Ingles
MULE 4000
Utility Vehicle
Service Manual
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Converter System 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Engine Bottom End 9 j
Transmission 10 j
Wheels/Tires 11 j
Final Drive 12 j
Brakes 13 j
Suspension 14 j
Steering 15 j
Frame 16 j
Utility Vehicle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Motorcycle & Engine 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.
© 2008 Kawasaki Heavy Industries, Ltd. 7th Edition (0) : Mar. 18, 2013
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)
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1), exhaust emission (2) and evaporative emission (3) 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 inlet manifold.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned to the bottom of the crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine family is engine modifications that
consist of fuel injection system and ignition system having optimum ignition timing characteristics.
The fuel injection system has been calibrated to provide lean air/fuel mixture characteristics and
optimum fuel economy with a suitable air cleaner and exhaust system.
A maintenance free injection system provides the most ignition timing and helps maintain a thor-
ough combustion process within the engine which contributes to a reduction of exhaust pollutants
entering the atmosphere.
3-1. Evaporative Emission Control System (other than CAL model and KAF620MB ∼/PB ∼)
The evaporative emission control system for this MULE utility vehicle consists of low permeation
fuel hoses.
3-2. Evaporative Emission Control System (CAL model and KAF620MB ∼/PB ∼)
The evaporative emission control system for this vehicle consists of low permeation fuel hoses
and fuel tank.
Also, vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere.
Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped.
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
(US Model only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective
inlet and exhaust silencing systems. They are designed to give optimum performance while
maintaining a low noise level. Please do not remove these systems, or alter them in any way
which results in an increase in noise level.
Foreword
This manual is designed primarily for use by Guide shows you all of the product’s system
trained mechanics in a properly equipped shop. and assists in locating their chapters. Each
However, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-
formation to make it useful to the owner who de- ble of Contents.
sires to perform his own basic maintenance and For example, if you want engine oil 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 Engine Lubrication System chapter. Then,
dures must be understood in order to carry out use the Table of Contents on the first page of
maintenance and repair satisfactorily. When- the chapter to find the Engine Oil section.
ever the owner has insufficient experience or Whenever you see these symbols, heed their
doubts his ability to do the work, all adjust- instructions! Always follow safe operating and
ments, maintenance, and repair should be car- maintenance practices.
ried out only by qualified mechanics.
DANGER
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor- DANGER indicates a hazardous situa-
oughly familiarize yourself with the procedures tion which, if not avoided, will result in
before starting work, and then do the work care- death or serious injury.
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift WARNING
tools or equipment. Precision measurements WARNING indicates a hazardous situa-
can only be made if the proper instruments are tion which, if not avoided, could result
used, and the use of substitute tools may ad- in death or serious injury.
versely affect safe operation.
For the duration of the warranty period, NOTICE
we recommend that all repairs and scheduled
maintenance be performed in accordance with NOTICE is used to address practices not
this service manual. Any owner maintenance or related to personal injury.
repair procedure not performed in accordance This manual contains four more symbols
with this manual may void the warranty. which will help you distinguish different types
To get the longest life out of your vehicle. of information.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled
maintenance.
○NOTE indicates information that may help
or guide you in the operation or service of
• Use proper tools and genuine Kawasaki Vehi-
cle parts. Special tools, gauges, and testers
the vehicle.
General Information
Table of Contents
1
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-10
Unit Conversion Table ............................................................................................................ 1-16
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly oper-
ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the vehicle, disconnect
the battery cables from the battery to prevent the engine
from accidentally turning over. Disconnect the ground cable
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) cable to the positive
(+) terminal of the battery then the negative (–) cable to the
negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High
flash-point solvent should be used according to directions
of the solvent manufacturer.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thor-
oughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
KAF620M9 Left Side View
The KAF620N is a camouflage-surface-treated model and identical to the KAF620M, the base
model, in every other aspect: controls, features, and specifications.
GENERAL INFORMATION 1-9
Model Identification
KAF620P9 Left Side View
Items KAF620P9 ∼ PE
Dimensions
Overall Length (KAF620P9 ∼ PC) 3 005 mm (118.31 in.)
(KAF620PD ∼) 2 965 mm (116.73 in.)
Overall Width 1 575 mm (62.01 in.)
Overall Height 1 925 mm (75.79 in.)
Wheelbase 1 870 mm (73.62 in.)
Track:
Front 1 160 mm (45.67 in.)
Rear 1 180 mm (46.46 in.)
Ground Clearance 190 mm (7.48 in.)
Seat Height 865 mm (34.45 in.)
Curb Mass: (KAF620P9 ∼ PA, US and CA) 595 kg (1 312 lb)
(KAF620P9 ∼ PA, CAL) (KAF620PB ∼ PC) 596 kg (1 314 lb)
(KAF620PD ∼) 606 kg (1 336 lb)
Front (KAF620P9 ∼ PC) 269 kg (593 lb)
(KAF620PD ∼) 277 kg (611 lb)
Rear (KAF620P9 ∼ PA, US and CA) 326 kg (719 lb)
(KAF620P9 ∼ PA, CAL) (KAF620PB ∼ PC) 327 kg (721 lb)
(KAF620PD ∼) 329 kg (725 lb)
(KAF620P9 ∼ PC) 23.5 L (6.2 US gal.)
Fuel Tank Capacity
(KAF620PD ∼) 24 L (6.3 US gal.)
Cargo Bed (L × W × H) (KAF620P9 ∼ PC) 1 175 × 1 310 × 288 mm (46.26 × 51.57 ×
11.34 in.)
(KAF620PD ∼) 1 175 × 1 310 × 290 mm (46.26 × 51.57 ×
11.42 in.)
Seating Capacity 2
Performance
Minimum Turning Radius 3.4 m (11.2 ft)
Engine
Type 4-stroke, OHV, 2-cylinders
Cooling System Liquid-cooled
Bore and Stroke 76 × 68 mm (2.99 × 2.68 in.)
Displacement 617 cm³ (37.6 cu in.)
Compression Ratio 10.3:1
Maximum Torque 47.0 N·m (4.8 kgf·m, 34.7 ft·lb) @2 500 r/min (rpm)
Fuel System FI (Fuel Injection) MIKUNI AC34
Fuel Type:
Minimum Octane Rating:
Antiknock Index (RON 87
+ MON)/2
Starting System Electric starter
Ignition System Battery and coil
Ignition Timing 5/750 ∼ 22/4 000 (BTDC°/rpm)
Cylinder Numbering Method Front to rear, 1-2
Firing Order Front to rear, 1-2
1-14 GENERAL INFORMATION
General Specifications
Items KAF620P9 ∼ PE
Valve Timing:
Inlet:
Open #1 68° BTDC/#2 64° BTDC
Close #1 76° ABDC/#2 80° ABDC
Duration 324°
Exhaust:
Open 94° BBDC
Close 48° ATDC
Duration 322°
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 1.8 L (1.9 US qt)
Drive Train
Primary Reduction System:
Type Belt drive torque converter
Reduction Ratio 3.9 ∼ 0.85
Transmission Gear Ratio:
Forward:
High 1.821 (51/28)
Reverse:
High 2.050 (41/20)
Final Drive System:
Type 1-speed, automatic, reverse gear drive (2WD)
Reduction Ratio (KAF620P9 ∼ PA) 5.4 (81/15)
(KAF620PB ∼) 5.492 (76/14)
Overall Drive Ratio:
Forward:
High (KAF620P9 ∼ PA) 8.360
(KAF620PB ∼) 8.404
Reverse:
High (KAF620P9 ∼ PA) 9.409
(KAF620PB ∼) 9.459
Transmission Oil:
Type API "GL-6" hypoid gear oil
Viscosity SAE 90: above 5°C (41°F) or
SAE 80: below 5°C (41°F)
Capacity 2.2 L (2.3 US qt)
Frame
Type Steel tube, Ladder
Caster (Rake Angle) 7.5°
Camber 0.8°
Trail 35 mm (1.4 in.)
GENERAL INFORMATION 1-15
General Specifications
Items KAF620P9 ∼ PE
Tire:
Front and Rear 23 × 11.00-10, Tubeless
Rim Size:
Front and Rear 10 × 8.5 AT
Steering Type Rack and pinion
Suspension:
Front:
Type MacPherson strut
Wheel Travel 100 mm (3.9 in.)
Rear:
Type De Dion axle
Wheel Travel 70 mm (2.8 in.)
Brake Type:
Front and Rear Drum (Hydraulic)
Parking Brake Type Drum (Mechanical internal expansion)
Electrical Equipment
Battery (US) 12 V 14 Ah
(CA) 12 V 18 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 35 W × 2
Brake/Tail Light 12 V 21/5 W × 2
Alternator:
Type Three-phase AC
Rated Output 23 A/12 V @3 000 r/min (rpm)
Load Capacity
Maximum Vehicle Load 603 kg (1 330 lb)
(Including Occupants and Cargo)
Maximum Cargo Bed Load 363 kg (800 lb)
Specifications are subject to change without notice, and may not apply to every country.
1-16 GENERAL INFORMATION
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
Units of Mass: kgf·m × 9.807 = N·m
kg × 2.205 = lb kgf·m × 7.233 = ft·lb
g × 0.03527 = oz kgf·m × 86.80 = in·lb
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart .............. 2-2 Engine Oil Change....................... 2-28
Torque and Locking Agent................. 2-4 Oil Filter Removal ........................ 2-29 2
Specifications .................................... 2-9 Oil Filter Installation ..................... 2-29
Special Tools ..................................... 2-11 Transmission .................................. 2-30
Periodic Maintenance Procedures..... 2-12 Transmission Oil Change............. 2-30
Fuel System.................................... 2-12 Wheels/Tires ................................... 2-30
Throttle Pedal Free Play Wheels Nuts Tightness
Inspection.................................. 2-12 Inspection.................................. 2-30
Throttle Pedal Free Play Tire Wear Inspection .................... 2-31
Adjustment ................................ 2-12 Final Drive....................................... 2-31
Full Throttle Pedal Position Front Final Gear Case Oil Change
Adjustment ................................ 2-13 (KAF620M/N) ............................ 2-31
Idle Speed Inspection .................. 2-13 Brakes............................................. 2-32
Air Cleaner Element Cleaning...... 2-14 Brake Fluid Level Inspection ....... 2-32
Air Cleaner Housing Dust or Brake Fluid Change ..................... 2-33
Water Draining .......................... 2-15 Brake Pedal Free Play Inspection 2-34
Fuel Hoses or Pipe and Brake Master Cylinder Cup and
Connections Inspection............. 2-15 Dust Seal Replacement ............ 2-35
Fuel Hoses Replacement............. 2-15 Brake Hose and Pipe Inspection.. 2-36
Evaporative Emission Control Brake Hose and Pipe
System Inspection (CAL Model Replacement ............................. 2-37
and KAF620MB ∼/PB ∼)............ 2-18 Brake Wear Inspection................. 2-38
Cooling System............................... 2-19 Brake Wheel Cylinder Assembly
Coolant Change ........................... 2-19 Replacement ............................. 2-39
Radiator Cleaning ........................ 2-22 Parking Brake Lever Travel
Water Hose and Connection Inspection.................................. 2-41
Inspection.................................. 2-22 Steering .......................................... 2-42
Engine Top End .............................. 2-23 Steering Wheel Free Play
Valve Clearance Inspection ......... 2-23 Inspection.................................. 2-42
Valve Clearance Adjustment........ 2-24 Steering Joint Dust Boot
Spark Arrester Cleaning............... 2-25 Inspection.................................. 2-42
Converter System ........................... 2-25 Frame ............................................. 2-43
Converter Air Cleaner Element Seat Belt Inspection ..................... 2-43
Cleaning/Inspection................... 2-25 Electrical System ............................ 2-43
Converter Dust or Water Draining 2-26 Spark Plug Cleaning/Inspection... 2-43
Converter Drive Belt Inspection ... 2-26 Spark Plug Gap Inspection .......... 2-43
Drive Belt Deflection Inspection ... 2-26 Brake Light Switch Inspection...... 2-44
Drive Belt Deflection Adjustment . 2-27 General Lubrication ........................ 2-44
Converter Driven Pulley Shoe Bolts, Nuts, and Fasteners ............. 2-45
Inspection.................................. 2-27 Tightness Inspection .................... 2-45
Engine Lubrication .......................... 2-28
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.
FREQUENCY Whichever
First
comes Regular Service
Service
first
→ Every
After 50 h, Every 250
↓ 500 h, or See
or 1 000 h, or 5 000
10 000 Page
Every km of use km of use
OPERATION km of use
ENGINE
Throttle pedal play - inspect • • 2-12
Idle speed - inspect • • 2-13
Air cleaner element - clean* • • 2-14
Air cleaner housing dust or water - drain* • • 2-15
Fuel hoses or pipe and connections -
inspect* • • 2-15
FREQUENCY Whichever
First
comes Regular Service
Service
first
→ After 50 Every 250 Every
↓ h, or 1 h, or 5 500 h, or See
000 km 000 km 10 000 Page
OPERATION Every of use of use km of use
CHASSIS
Wheel nuts tightness - inspect • • 2-30
Tire wear - inspect* • • 2-31
Front final gear case oil - change* 1 year • • 2-31
Brake fluid level - inspect • • 2-32
Brake fluid - change 2 years 2-33
Brake pedal play - inspect* • • 2-34
Brake master cylinder cup and dust seal
2 years 2-35
- replace
Brake hose and pipe - inspect • • 2-36
Brake hose - replace 4 years 2-37
Brake wear - inspect* • 2-38
Brake wheel cylinder assembly - replace 2 years 2-39
Parking brake lever - inspect • • 2-41
Steering - inspect • • 2-42
Steering and axle shaft joint dust boots
- inspect • • 2-42
•*:: Service
Clean, adjust, lubricate, torque, or replace parts as necessary.
more frequently when operated in mud, dust, or other harsh riding conditions.
2-4 PERIODIC MAINTENANCE
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.
Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System
Air Cleaner Housing Bolts 20 2.0 15
Control Panel Cover Bolts 4.0 0.41 35 in·lb
ECU Mounting Bolts 8.8 0.90 78 in·lb
Throttle Lever Mounting Nut 6.9 0.70 61 in·lb R
Water Temperature Sensor 22 2.2 16
Throttle Sensor Screws 3.5 0.36 31 in·lb
Subthrottle Valve Actuator Cover Screws 2.0 0.20 18 in·lb
Canister Bracket Mounting Bolts (CAL and
8.8 0.90 78 in·lb
KAF620MB ∼/PB ∼)
Canister Mounting Bolts (CAL and KAF620MB
19.6 2.0 14
∼/PB ∼)
Fuel Pump Mounting Bolts 4.0 0.41 35 in·lb
Breather Mounting Bolt (KAF620ME/PE) 8.8 0.90 78 in·lb
Dipstick Pipe Bolt (KAF620ME/PE) 8.8 0.90 78 in·lb
Cooling System
Coolant Drain Plugs 17 1.7 13
Coolant Reservoir Mounting Bolt 4.4 0.45 39 in·lb
Radiator Fan Mounting Bolts 4.9 0.50 43 in·lb
Radiator Mounting Bolts 8.8 0.90 78 in·lb
Radiator Screen Bolts 8.8 0.90 78 in·lb
Water Pipe Bolts 8.8 0.90 78 in·lb
Water Pump Cover Bolt (M8) 25 2.5 18 S
Water Pump Cover Bolts (M6) 8.8 0.90 78 in·lb S
Water Pump Housing Bolt 8.8 0.90 78 in·lb
Engine Top End
Valve Adjusting Screw Locknuts 9.8 1.0 87 in·lb
Cylinder Head Bolts 22 2.2 16 S
Cylinder Head Plug 22 2.2 16
Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb
Exhaust Pipe Holder Nuts 8.8 0.90 78 in·lb
Muffler Mounting Bolts 19.6 2.0 14
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Converter System
Drive Pulley Bolt 76 7.7 56 R
Drive Pulley Cover Bolts 12.5 1.3 111 in·lb
Driven Pulley Bolt 93 9.5 69 L
Wear Shoe Screws 1.1 0.11 9.7 in·lb L
Ramp Weight Nuts 6.9 0.70 61 in·lb R
Spider 275 28.0 203
Air Cleaner Gousing Bolts (KAF620MA/PA Late
16 1.6 12
Models and KAF620MB ∼/PB ∼)
Air Cleaner Housing Bolts (KAF620M9/N9/P9 and
20 2.0 15
KAF620MA/PA Early Models)
Converter Case Bolts 20 2.0 15
Converter Cover Bolts (Converter Cover without
7.0 0.71 62 in·lb
Collars)
Converter Cover Bolts (Converter Cover with
8.8 0.90 78 in·lb
Collars)
Cooling Fan Cover Bolts 8.8 0.90 78 in·lb
Heat Guard Plate Bolts 8.8 0.90 78 in·lb
Engine Lubrication System
Oil Pressure Switch 9.8 1.0 87 in·lb SS
Engine Oil Drain Plug (M16) 22 2.2 16
Engine Oil Drain Plug (M14) 32 3.3 24
Crankcase Cover Bolts 25 2.5 18
Oil Filter 17.6 1.8 13 EO
Oil Filler Pipe Bolts 4.4 0.45 39 in·lb
Oil Filter Stud Bolt 27 2.8 20
Dipstick Pipe Bolt (KAF620ME/PE) 8.8 0.90 78 in·lb
Engine Removal/Installation
Engine Mounting Bolts 44 4.5 32
Engine Positioning Plate Bolts 20 2.0 15
Engine Bottom End
Connecting Rod Big End Cap Bolts 21 2.1 15 EO
Coolant Drain Plugs 17 1.7 13
Crankcase Cover Bolts 22 2.2 16
Oil Filter Stud Bolt 27 2.8 20
Dipstick Pipe Bolt (KAF620ME/PE) 8.8 0.90 78 in·lb
Transmission
Differential Gear Housing Bolts 57 5.8 42 L
Shift Arm Positioning Bolt 36.5 3.7 27
Shift Shaft Lever Clamp Bolts 12 1.2 106 in·lb
Shift Shaft Stop Bolts 7.8 0.80 69 in·lb
Bearing Holder 118 12.0 87.0 MO
Engine Positioning Plate Bolts 20 2.0 15
Hi/Low Gear Case Bolts 20 2.0 15
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Neutral Switch 15 1.5 11
Transmission Case Bolts 8.8 0.90 78 in·lb
Transmission Case Mounting Nuts 44.1 4.5 33 R
Transmission Oil Drain Plug 15 1.5 11
(KAF620P)
Engine Positioning Plate Bolts 20 2.0 15
Neutral Switch 15 1.5 11
Shift Arm Positioning Bolt 36.5 3.7 27
Shift Shaft Lever Clamp Bolt 12 1.2 106 in·lb
Speed Sensor Bolt 8.8 0.90 78 in·lb
Transmission Case Bolts 8.8 0.90 78 in·lb
Transmission Oil Drain Plug 15 1.5 11
Wheels/Tires
Wheel Nuts (KAF620M9 ∼ MB/N9/P9 ∼ PB) 137 14 101
Wheel Nuts (KAF620MC ∼/PC ∼) 110 11.2 81.1
Final Drive
Front Final Gear Case (KAF620M/N):
Differential Case Torx Bolts 32 3.3 24
Front Axle Cap Bolts 8.8 0.90 78 in·lb
Gear Case Bracket Bolts 44.1 4.5 33
Gear Case Mounting Nuts 44.1 4.5 33 R
Oil Drain Plug 20 2.0 15
Oil Filler Cap 29 3.0 21
Pinion Gear Bearing Housing Nuts 25 2.5 18
Pinion Gear Slotted Nut 118 12.0 87.0 MO
Ring Gear Bolts 49 5.0 36
Ring Gear Cover Bolts (M10) 47 4.8 35 S
Ring Gear Cover Bolts (M8) 25 2.5 18 S
Bevel Gear Case (KAF620M/N):
Bearing Holder 118 12.0 87.0 L
Bevel Gear Case Bolts 22 2.2 16
Bevel Gear Case Holder Nuts 25 2.5 18
Drive Gear Nut 118 12.0 87.0 MO
Driven Gear Shaft Nut 108 11.0 79.7 L
Housing Locknut 118 12.0 87.0 L
Propeller Shaft Bearing Housing Cover Bolts 3.4 0.35 30 in·lb
Speed Sensor Bolt 8.8 0.90 78 in·lb
Drive Shaft Cap Bolts 20 2.0 15
Brakes
Bleed Valves 7.8 0.80 69 in·lb
Brake Hose Banjo Bolts 25 2.5 18
Brake Panel Mounting Bolts 44.1 4.5 33 L
Brake Pipe Nipples 17.7 1.8 13 B
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Front Axle Nuts 196 20.0 145
Master Cylinder Push Rod Locknut 17.2 1.8 13
Master Cylinder Reservoir Cap 3.5 0.36 31 in·lb
Piston Stop Bolt 8.9 0.91 79 in·lb
Reservoir Clamp Bolt 6.2 0.63 55 in·lb
Wheel Cylinder Mounting Bolts 10.3 1.1 91 in·lb
Rear Axle Nuts 304 31.0 224
Wheel Cylinder Mounting Nuts 7.4 0.75 65 in·lb
Suspension
Damper Bracket Mounting Nuts 59 6.0 44 R, S
Front Suspension Arm Joint Nuts 78 8.0 58
Front Suspension Arm Pivot Bolts 98 10.0 72.3
Leaf Spring Mounting Nuts (Front) 98 10.0 72.3
Leaf Spring Mounting Nuts (Rear) 59 6.0 44
Rear Shock Absorber Mounting Nuts 59 6.0 44 R
Strut Clamp Nuts 98 10.0 72.3
Strut Locknuts 50 5.1 37
Strut Mounting Nuts 44 4.5 32 R
Tie-Rod End Nuts 34 3.5 25
Steering
EPS Unit Mounting Bolts (KAF620M/N) 20 2.0 15
Intermediate Shaft Clamp Bolts (KAF620P) 20 2.0 15
Rack Guide Spring Cap Locknut 39 4.0 29
Steering Gear Assembly Bracket Bolts 52 5.3 38 L
Steering Wheel Mounting Nut 52 5.3 38 R
Strut Clamp Nuts 98 10.0 72.3
Tie-Rod End Locknuts 44 4.5 32
Tie-Rod End Nuts 34 3.5 25
Universal Joint Clamp Bolts (KAF620M/N) 20 2.0 15
Frame
Battery Holder Nuts 2.0 0.20 18 in·lb
Front Bar Mounting Bolts (Lower) 98 10.0 72.3
Front Bar Mounting Bolts (Upper) 44 4.5 32
Rear Bar Mounting Bolts 44 4.5 32
Rear Bar Mounting Nuts 44 4.5 32
Seat Belt Buckle Mounting Bolts 34.3 3.5 25
Seat Belt Mounting Bolts 34.3 3.5 25
Rear End Subframe Mounting Nuts 44.1 4.5 33 R
Tail Gate Fixing Lever Screws 4.4 0.45 39 in·lb L
Electrical System
Alternator Rotor Nut 118 12.0 87.0
Battery Holder Nuts 2.0 0.20 18 in·lb
Neutral Switch 15 1.5 11
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Oil Pressure Switch 9.8 1.0 87 in·lb SS
Spark Plugs 17 1.7 13
Speed Sensor Bolt 8.8 0.90 78 in·lb
Starter Motor Cable Terminal Nut 8.8 0.90 78 in·lb
Starter Motor Mounting Bolts 21.6 2.2 16
ECU Mounting Bolts 8.8 0.90 78 in·lb
Regulator/Rectifier Mounting Bolts 8.8 0.90 78 in·lb
Water Temperature Sensor 22 2.2 16
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. Torque
Mark of bolt head
mm (in.) N·m kgf·m ft·lb
6 (0.24) 4T 3.9 ∼ 4.9 0.40 ∼ 0.50 35 ∼ 43 in·lb
6 (0.24) 7T 7.8 ∼ 9.8 0.80 ∼ 1.0 69 ∼ 87 in·lb
6 (0.24) 9T 12 ∼ 15 1.2 ∼ 1.5 104 ∼ 130 in·lb
8 (0.31) 4T 10 ∼ 14 1.0 ∼ 1.4 87 ∼ 120 in·lb
8 (0.31) 7T 18 ∼ 22 1.8 ∼ 2.2 13 ∼ 16
10 (0.39) 4T 20 ∼ 24 2.0 ∼ 2.4 14 ∼ 17
10 (0.39) 7T 39 ∼ 44 4.0 ∼ 4.5 29 ∼ 33
NOTE
○If the throttle pedal free play cannot be adjusted by us-
ing the adjuster at the cable lower end, use the cable
adjuster [A] at the cable upper end. Do not forget to se-
curely tighten the adjuster mounting nuts [B].
PERIODIC MAINTENANCE 2-13
Periodic Maintenance Procedures
Full Throttle Pedal Position Adjustment
• Loosen the locknut [A].
• Screw in the throttle pedal stop bolt [B].
• carburetortheis throttle
Depress pedal until the throttle lever on the
in the fully opened position, and keep its
position.
• Turn the throttle pedal stop bolt until the bolt head lightly
touches the bottom of the throttle pedal.
• Tighten the locknut securely.
NOTE
○The idle speed is controlled by ECU. Therefore do not
adjust with the throttle lever stopper screw [A].
If the idle speed is out of the specified range, check the
throttle lever stopper screw position.
Throttle Lever Stopper Screw Position
•Remove:
Control Panel Cover Bolts [A]
Control Panel Cover [B]
• Unhook the hook [A] from the throttle link rod [B] and re-
move the rod from throttle lever [C].
• Check the idle speed with a precise tachometer.
If the idle speed is within the specified range, continue the
following procedures.
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Remove:
Element [A]
• Clean the element by tapping gently with the handle end
of a screwdriver.
If the element is very dirty or damaged, replace the ele-
ment.
• Carefully clean out the air cleaner cover.
• Reset the Air Filter Restriction Gauge [A] (push [B] its
reset button).
• Pull out the fuel joint [A] from the fitting while pushing
strongly both stoppers [B].
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
• Pull
of it.
up the joint lock [A] while opening the lower sides [B]
• Insert the fuel hose joint [A] straight onto the fitting [B] until
the hose joint clicks.
• Push down [A] the joint lock [B] until the joint lock clicks.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Push and pull [A] the fuel hose joint [B] back and forth
more than two times and make sure it is locked and does
not come off.
WARNING
Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.
If it comes off, reinstall the hose joint.
• Start the engine and check the fuel hose for leaks.
• For the check valve hoses, fit the fuel hose [A] onto the fit-
ting fully and install the plate clamp [B] beyond the raised
rib [C].
1 ∼ 2 mm (0.039 ∼ 0.078 in.) [D]
• The hose end must reach the filler [E] or be as near as
possible to the step [F].
• Remove:
Quick Rivets [A]
Tapping Screw [B] and Collar
Partition [C]
• Remove:
Coolant Reserve Tank Mounting Bolt [A]
Cap [B]
• Poor the coolant into a container.
• Remove:
Radiator Cap [A]
○Remove the radiator cap in two steps. First turn the cap
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.
NOTICE
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.
NOTE
○Choose a suitable mixture ratio by referring to the
coolant manufacture’s directions.
• When the coolant begins to flow out the air bleeder bolt
holes, tighten the air bleeder bolts.
• Fill the cooling system up to the filler neck [A] in the radi-
ator cap fitting with coolant.
• Install the radiator cap.
• Bleed the
Fill the reserve tank up to the F (Full) mark with coolant.
•○Start the engine
air from the cooling system as follows.
and run it until no more air bubbles can
be seen in the coolant in the reserve tank (less than five
minutes).
○Tap the radiator hoses to force any air bubbles caught
inside.
○Stop the engine and fill the reserve tank up to the F (Full)
mark with coolant.
NOTICE
Do not add more coolant above the F (Full) mark.
• Remove:
Front Cover (see Front Cover Removal in the Frame
chapter)
Radiator Screen Mounting Bolts [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.
NOTICE
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core .
Hold the steam gun perpendicular to the core sur-
face.
Run the steam gun following the core fin direction.
• Remove:
Alternator Cover [A] (see Alternator Rotor and Stator Re-
moval in the Electrical System chapter)
• Remove:
Bolt [A]
Cylinder Head Cover (Rear) [B]
Spark Plug [C]
• Remove:
Bolts [A]
• Remove:
Bolts [A]
Cylinder Head Cover (Front) [B]
Spark Plug [C]
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the element in a well-ventilated area,
and take care that there is no spark or flame any-
where near the working areas. Do not use gasoline
or low flash-point solvents to clean the element.
Engine Lubrication
Engine Oil 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.
• completely.
Remove the engine oil drain plug [A], and let the oil drain
NOTE
○Depending on the atmospheric temperature of your rid-
ing area, the engine oil viscosity should be changed ac-
cording to the chart:
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for the engine.
PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
Oil Filter Removal
• Tilt up the cargo bed.
•○Remove the oil filter [A].
When unscrewing the oil filter, cover the filter bottom with
a clean cloth so as not to spill the engine oil out of the
filter. Any split oil should be wiped up completely.
○Use the oil filter wrench [A] if the oil filter is tight.
Special Tool - Oil Filter Wrench: 57001-1249
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: 137 N·m (14.0 kgf·m, 101 ft·lb)
○Tighten the wheel nuts [1] ∼ [4] in a criss-cross pattern.
PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
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
Standard: 13.2 mm (0.52 in.)
Service Limit: 3 mm (0.12 in.)
Standard Tire
Front and Rear: 23 × 11.00-10 DUNLOP KT869
Tubeless
23 × 11.00-10 DURO DI–K968
Tubeless
Final Drive
Front Final Gear Case Oil Change (KAF620M/N)
• 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 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
Oil on tires can cause loss of traction and an ac-
cident resulting in serious injury or death. When
draining or filling the final gear case, do not spill oil
the tire or rim. Clean any oil that may spill with a
high flash-point solvent.
• After the oil has completely drained out, install the drain
plug with a new aluminum gasket, and tighten it.
Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Fill the gear case up to the bottom [A] of filler opening [B]
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 and GL-6" indicate a quality and additive rating.
• Be sure the O-ring [A] is in place, and tighten the filler cap.
Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 21 ft·lb)
Filler Opening [B]
• Install the front final gear case skid plate (see Front Final
Gear Case Oil Level Inspection in the Final Drive chapter).
Brakes
Brake Fluid Level Inspection
• 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
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
• 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
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake pedal has a soft or "spongy" feel-
ing mushy when it is applied, there might be air in
the brake lines or the brake may be defective. Do
not operate the vehicle and service the brake sys-
tem immediately.
• Remove:
Front Cargo Compartment (see Front Cargo Compart-
ment Removal in the Frame chapter)
• Loosen the locknut [A] and turn the push rod [B] to obtain
the correct amount of free play.
• Tighten:
Torque - Master Cylinder Push Rod Locknut: 17.2 N·m (1.8
kgf·m, 13 ft·lb)
• Check for the brake drag and braking effectiveness.
WARNING
Insufficient free play can cause brake heating and
drag, resulting in skidding and loss of control which
could cause an accident resulting in serious injury
or death. Be sure the brake free play is adjusted to
the specification.
PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Brake Master Cylinder Cup and Dust Seal
Replacement
• Remove the master cylinder (see Master Cylinder Re-
moval in the Brakes chapter).
• Push the pistons in all the way with a screwdriver and
remove the piston stop bolt [A] and washer [B].
• Remove the dust seal [C] and then retainer [D] with the
circlip pliers.
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the piston assembly by lightly applying com-
pressed air to where the brake pipe fits into the cylinder.
Pistons [E]
Springs [F]
Secondary Cups [G]
Primary Cups [H]
Master Cylinder [I]
• Remove:
Brake Shoe Spring [A]
Brake Shoe [B]
○Push the shoe hold-down springs [C] and twist the pins
[D] to remove the shoes.
NOTE
○Hold the brake shoes with a clean cloth to protect the
linings from grease or dirt.
• Release
position.
the parking brake and return the lever to its rest
• Loosen the locknut [A] and turn the adjusting nut [B] to
obtain the correct amount of lever travel.
• Tighten the locknut.
• Check for brake drag and braking effectiveness.
WARNING
Insufficient free play can cause brake heating and
drag, resulting in skidding and loss of control which
could cause an accident resulting in serious injury
or death. Be sure the brake free play is adjusted to
the specification.
NOTE
○If the parking brake lever travel cannot be adjusted by
using the adjusting nut at the lever, use the adjusters
[A] at the parking brake lever and rear wheels. Do not
forget to adjust both the left and right cables evenly, and
then securely tighten the adjuster mounting nuts [B].
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering
Steering Wheel Free Play 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 Wheel Cen-
tering in the Steering chapter)
Universal Joint Clamp Bolts (KAF620M/N) (see Ex-
ploded View in the Steering chapter)
EPS Unit Mounting Bolts (KAF620M/N) (see EPS Unit
Installation in the Steering chapter)
Intermediate Shaft Clamp Bolts (KAF620P) (see Steer-
ing Wheel and Main Shaft Installation in the Steering
chapter)
Steering Gear Assembly Mounting Bracket Bolts (see
Steering Gear Assembly Installation in the Steering
chapter)
Steering Gear Assembly Mounting Rubber Dampers
Tie-rod End Nuts (see Toe-in Adjustment in the
Wheels/Tires chapter)
Steering Gear Preload Adjustment (see Steering Gear
Pleload Adjustment in the Steering chapter)
If the inspections above check out good but the free play
is out of the specified, the steering gear assembly is dam-
aged 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.
PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Frame
Seat Belt Inspection
• Check the belt [A] for damage or tear.
If necessary, replace the belt with a new one.
Electrical System
Spark Plug Cleaning/Inspection
• Remove the spark plug (see Spark Plug Removal/Instal-
lation in the Electrical System chapter).
• The plug may also be cleaned using a high flash-point
solvent and a nonmetal brush (nylon etc.).
If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked, replace the plug. Use the
standard spark plug or its equivalent.
Spark Plug Gap Inspection
• Measure the gap [A] with a wire-type thickness gauge.
If the gap is incorrect, carefully bend the side electrode
[B] with a suitable tool to obtain the correct gap.
Spark Plug Gap
Standard: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
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].
NOTICE
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.
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Air Cleaner Housing Bolts 20 2.0 15
2 Breather Mounting Bolt (KAF620ME/PE) 8.8 0.9 78 in·lb
3 Dipstick Pipe Bolt (KAF620ME/PE) 8.8 0.9 78 in·lb
4. KAF620M9/N9/P9, MA/PA
5. KAF620MB ∼ MD/PB ∼ PD
CL: Apply cable lubricant.
G: Apply grease.
SS: Apply silicone sealant.
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Control Panel Cover Bolts 4.0 0.41 35 in·lb
2 ECU Mounting Bolts 8.8 0.90 78 in·lb
3 Throttle Lever Mounting Nut 6.9 0.70 61 in·lb R
4 Water Temperature Sensor 22 2.2 16
5 Throttle Sensor Screws 3.5 0.36 31 in·lb
6 Subthrottle Valve Actuator Cover Screws 2.0 0.20 18 in·lb
7. KAF620M9/N9/P9, MA/PA
8. KAF620MD/PD Late Models and KAF620ME/PE
9. KAF620MB ∼ MD/PB ∼ PD
10. KAF620M9 ∼ MD/N9/P9 ∼ PD
R: Replacement Parts
3-8 FUEL SYSTEM (DFI)
Exploded View (KAF620M9 ∼ MC/N9/P9 ∼ PC)
FUEL SYSTEM (DFI) 3-9
Exploded View (KAF620M9 ∼ MC/N9/P9 ∼ PC)
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Canister Bracket Mounting Bolts 8.8 0.90 78 in·lb
2 Canister Mounting Bolts 19.6 2.0 14
3 Fuel Pump Mounting Bolts 4.0 0.41 35 in·lb
4. KAF620M9/N9/P9, MA/PA (US and CA Models)
5. KAF620M9/N9/P9, MA/PA
6. KAF620M9/N9/P9, MA/PA (CAL Model)
AD: Apply adhesive.
R: Replacement Parts
3-10 FUEL SYSTEM (DFI)
Exploded View (KAF620MD ∼/PD ∼)
FUEL SYSTEM (DFI) 3-11
Exploded View (KAF620MD ∼/PD ∼)
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Canister Bracket Mounting Bolts 8.8 0.90 78 in·lb
2 Canister Mounting Bolts 19.6 2.0 14
3 Fuel Pump Mounting Bolts 4.0 0.41 35 in·lb
AD: Apply adhesive.
R: Replacement Parts
3-12 FUEL SYSTEM (DFI)
Specifications
Item Standard
Digital Fuel Injection System
Idle Speed 950 ±50 r/min (rpm)
Throttle Body Assy:
Throttle Valve Dual throttle valve
Bore:
Main Throttle 34 mm (1.34 in.)
Subthrottle 30 mm (1.18 in.)
ECU (Electronic Control Unit)
Make DENSO
Digital memory type, with built in IC igniter, sealed
Type
with resin
Main Throttle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 0.89 ∼ 1.13 V at throttle closing
DC 3.81 ∼ 4.11 V at full throttle opening (reference
value)
Resistance In the text
Subthrottle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 0.58 ∼ 0.82 V at subthrottle valve closing
DC 3.81 ∼ 4.11 V at subthrottle valve opening
(reference value)
Resistance In the text
Subthrottle Valve Actuator
Resistance About 120 Ω at 25°C (77°F)
Inlet Air Pressure Sensor
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 3.46 ∼ 3.82 V at standard atmospheric pressure
(see this text for details)
Inlet Air Temperature Sensor:
Output Voltage About DC 2.0 ∼ 2.5 V at 20°C (68°F)
Resistance 2.21 ∼ 2.69 kΩ at 20°C (68°F)
0.290 ∼ 0.354 kΩ at 80°C (176°F) (reference value)
Water Temperature Sensor:
Output Voltage About DC 2.0 ∼ 2.5 V at 20°C (68°F)
Resistance 2.32 ∼ 2.59 kΩ at 20°C (68°F)
310 ∼ 326 Ω at 80°C (176°F)
139.9 ∼ 143.5 Ω at 110°C (230°F)
Speed Sensor:
Item Standard
Ignition Coils:
Input Voltage Battery Voltage
Fuel Pressure (High Pressure Line) 285 ∼ 315 kPa (2.9 ∼ 3.2 kgf/cm², 41 ∼ 46 psi) with
engine idling
Fuel Pump:
Type Wesco pump
Discharge 50 mL (1.7 US oz.) or more for 3 seconds
Fuel Injectors:
Type INP-259
Nozzle Type Fine atomizing type with 4 holes
Resistance About 11.7 ∼ 12.3 Ω at 20°C (68°F)
Throttle Pedal and Cable
Throttle Pedal Free Play 5 ∼ 10 mm (0.20 ∼ 0.39 in.)
Air Cleaner
Air Cleaner Element Paper element
3-14 FUEL SYSTEM (DFI)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: Measuring Adapter:
57001-125 57001-1700
Terminal Names
1. Water Temperature Sensor: O
2. Inlet Air Pressure Sensor: G/Y
3. Power Supply to ECU: W/Y
4. Subthrottle Sensor: Y/W
5. Power Supply to Sensors: BL/R
6. Main Throttle Sensor: BR/BL
7. ECU Ground: BK/Y
8. Battery (+): W
9. Crankshaft Sensor (+): Y
10. Unused
11. Unused
12. Speed Sensor (+): P
13. Fuel Pump Relay: BR/Y
14. Fuel Injector #2: O/G
15. Fuel Injector #1: O/R
16. Ignition Coil #2: W
17. Ignition Coil #1: BL
18. Inlet Air Temperature Sensor: R
19. Neutral Switch: LG
20. Water Temperature Indicator Light: BL/W
21. Subthrottle Sensor: Y/R
22. Main Throttle Sensor: BR/R
23. Kawasaki Diagnostic System Line (in KDS Connector): LB
24. Ground for Sensors: BR/BK
25. Self-diagnosis Terminal (in KDS Connector): LG/BK
26. Crankshaft Sensor (–): G/W
27. FI Indicator Light: LG/G
28. Radiator Fan Relay: BK/BL
29. Speed Sensor (–): BK
30. Subthrottle Valve Actuator: P/BK
31. Subthrottle Valve Actuator: BK/BL
32. Subthrottle Valve Actuator: W/BL
33. Subthrottle Valve Actuator: G
34. Ground for Ignition System: BK/Y
FUEL SYSTEM (DFI) 3-19
DFI Parts Location
Main Throttle Sensor [A]
Subthrottle Sensor [B]
Subthrottle Valve Actuator [C]
Water Temperature Sensor [D]
Inlet Air Temperature Sensor [E]
○Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memo-
rizes service codes.
○Do not spray water on the electrical parts, DFI parts, con-
nectors, leads and wiring.
○If a transceiver is installed on the vehicle, make sure that
the operation of the DFI system is not influenced by elec-
tric wave radiated from the antenna. Check operation of
the system with the engine at idle. Locate the antenna as
far as possible away from the ECU.
○When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer sur-
faces of these parts clean with compressed air.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
○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.
○Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.
FUEL SYSTEM (DFI) 3-23
DFI Servicing Precautions
○To maintain the correct fuel/air mixture (F/A), there must
be no inlet air leaks in the DFI system. Be sure to install
the oil filler cap [A] and dipstick [B] after filling the engine
oil.
3-24 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Outline
When an abnormality in the DFI system occurs, the DFI
warning indicator light [A] goes on to alert the driver. In ad-
dition, the condition of the problem is stored in the memory
of the ECU (electronic control unit).
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
[C] KAF620MD ∼/PD ∼
NOTICE
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
○If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the con-
tinuity between the end [E] and the ground [F]. This en-
ables to check a long harness for continuity. If the harness
is open, repair or replace the harness.
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.
3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.):
Year of initial registration: Model:
Engine No.: Frame No.:
Date problem occurred: Mileage:
Environment when problem occurred.
Weather □fine, □cloudy,□rain, □snow, □always, □other:
Temperature □hot, □warm, □cold, □very cold, □always
Problem □chronic, □often, □once
frequency
Road □street, □mountain road (□uphill, □downhill), □bumpy, □pebble
Altitude □normal, □high (about 1 000 m or more)
Vehicle conditions when problem occurred.
DFI warning □lights up immediately after ignition switch ON, and goes off after 1 ∼ 2 seconds
indicator light (normal).
□lights up immediately after ignition switch ON, and stays on (DFI problem).
□lights up immediately after ignition switch ON, but goes off after about 10 seconds
(DFI problem).
□unlights (light, ECU or its wiring fault).
□sometimes lights up (probably wiring fault).
Starting □starter motor not rotating.
difficulty □starter motor rotating but engine doesn’t turn over.
□starter motor and engine don’t turn over.
□no fuel flow (□no fuel in tank, □no fuel pump sound).
□engine flooded (do not crank engine with throttle opened, which promotes engine
flooding).
□no spark.
□other:
Engine stops □right after starting.
□when opening throttle pedal.
□when closing throttle pedal.
□when moving off.
□when stopping the vehicle.
□when cruising.
□other:
Poor running □very low idle speed, □very high idle speed, □rough idle speed
at low speed □battery voltage is low (charge the battery).
□spark plug loose (tighten it)
□spark plug dirty, broken, or gap maladjusted (remedy it).
□backfiring
□afterfiring
□hesitation when acceleration
□engine oil viscosity too high
□brake dragging
□engine overheating
□other:
FUEL SYSTEM (DFI) 3-29
Troubleshooting the DFI System
Dealer Mode
The DFI warning indicator light emits the service code(s)
[A] to show the problem(s) which the DFI system and igni-
tion system has at the moment of diagnosis.
Self-diagnosis Procedures
○When a problem occurs with the DFI system and ignition
system, the DFI warning indicator light [A] goes on.
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
[C] KAF620MD ∼/PD ∼
NOTE
○Use a fully charged battery when conducting
self-diagnosis. Otherwise, the light blinks very slowly
or does not blink.
○Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.
3-36 FUEL SYSTEM (DFI)
Self-Diagnosis
• Turn the sensor clockwise until the sensor screw holes [A]
align with screw holes in the body.
• Tighten the main throttle sensor screws [B] lightly.
• Check to see that the throttle lever [A] contacts [B] the
stop screw.
If it does not contact the throttle lever, close the throttle
valve with your finger.
NOTE
○Do not adjust the position of the stop screw [C]. If the
stop screw has been adjusted, see the Stop Screw Re-
placement.
• Adjust [A] the position of the sensor [B] until the lower of
two voltage readings meets below Main Throttle Sensor
Output Voltage Specification.
Main Throttle Sensor Output Voltage
Specification: 1.01 ±0.02 V
Example:
Reading 1 voltage = 1.02 V
Reading 2 voltage = 0.90 V
○As the Reading 2 is lower than Reading 1, adjust the sen-
sor position so that the Reading 2 becomes 1.01 ± 0.02
V.
• Once the sensor is properly adjusted, tighten the main
throttle sensor screws [C].
NOTE
○Hold the sensor when tightening the main throttle sen-
sor screws.
• Tighten:
Torque - Main Throttle Sensor Screws: 3.5 N·m (0.36 kgf·m,
31 in·lb)
• Re-measure the output voltages again to verify the volt-
age readings are within the specifications.
• Remove the measuring adapter and reconnect the sensor
connector.
Main Throttle Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnect
Tilt up the cargo bed.
• the main throttle sensor connector [A].
Connections:
BR/BL lead of Main
(l) Digital Meter (+) →
Harness
BR/BK lead of Main
Digital Meter (–) →
Harness
(ll) Digital Meter (+) → BR/R lead of Main Harness
BR/BK lead of Main
Digital Meter (–) →
Harness
• Turn the sensor clockwise until the sensor screw holes [A]
align with screw holes in the body.
• Tighten the subthrottle sensor screws [B] lightly.
• Remove:
Bolts [A] and Control Panel Cover [B]
FUEL SYSTEM (DFI) 3-47
Main Throttle Sensor, Subthrottle Sensor and Subthrottle Valve Actuator (Ser-
vice Code 11)
• Remove:
Fuel Injector Connector [A]
Subthrottle Valve Actuator Connector [B]
Clamp [C]
• Disconnect the breather hose [D]. (KAF620M9 ∼
MD/N9/P9 ∼ PD)
• Remove:
Clamps [E] (KAF620M9 ∼ MD/N9/P9 ∼ PD)
• Remove:
Screws [A]
Subthrottle Valve Actuator Cover [B]
○The subthrottle valve actuator lead connector in the cover
need not be removed.
•Connect the fuel injector connector to fuel injector.
NOTE
○Do not connect the subthrottle valve actuator connector
yet.
• Adjust [A] the position of the sensor [B] until the higher
of two voltage readings meets below Subthrottle Sensor
Output Voltage Specification.
Subthrottle Sensor Output Voltage
Specification: 0.70 ±0.02 V
Example:
Reading 1 voltage = 1.02 V
Reading 2 voltage = 1.13 V
○As the Reading 2 is higher than Reading 1, adjust the
sensor position so that the Reading 2 becomes 0.70 ±
0.02 V.
• Once the sensor is properly adjusted, tighten the subthrot-
tle sensor screws [C].
NOTE
○Hold the sensor when tightening the subthrottle sensor
screws.
• Tighten:
Torque - Subthrottle Sensor Screws: 3.5 N·m (0.36 kgf·m,
31 in·lb)
• Re-measure the output voltages again to verify the volt-
age readings are within the specifications.
• Remove the measuring adapter and reconnect the sensor
connector.
Connections to Adapter:
(l) Digital Meter (+) → Y/R lead of Main Harness
BR/BK lead of Main
Digital Meter (–) →
Harness
(ll) Digital Meter (+) → Y/W lead of Main Harness
BR/BK lead of Main
Digital Meter (–) →
Harness
• Visually
[A].
inspect the subthrottle valve actuator mechanism
• Move the lever [A] by finger lightly, and check that the
subthrottle valve [B] opens and closes smoothly.
If the lever and valve do not move smoothly, replace the
throttle body assy.
When the code 11 appears even if the throttle body assy
is replaced and when the main throttle sensor, subthrottle
sensor and subthrottle valve actuator are good, replace
the ECU.
3-54 FUEL SYSTEM (DFI)
Main Throttle Sensor, Subthrottle Sensor and Subthrottle Valve Actuator (Ser-
vice Code 11)
Throttle Sensors and Subthrottle Valve Actuator Circuit
1. ECU
2. Main Throttle Sensor
3. Subthrottle Sensor
4. Subthrottle Valve Actuator
5. Power Source
FUEL SYSTEM (DFI) 3-55
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Removal
NOTICE
Never drop the inlet air pressure sensor, especially
on a hard surface. Such a shock to the sensor can
damage it.
• Remove:
Inlet Air Pressure Sensor [A] (Upward)
Installation)
NOTE
○Depending on the local atmospheric pressure, the out-
put voltage should be changed according to the chart.
[Vout]: Output Voltage
[Popt]: Local Atmospheric Pressure
1. ECU
2. Inlet Air Pressure Sensor
3-58 FUEL SYSTEM (DFI)
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Removal
NOTICE
Never drop the inlet air temperature sensor, espe-
cially on a hard surface. Such a shock to the inlet
air temperature sensor can damage it.
1. ECU
2. Inlet Air Temperature Sensor
3-60 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal
NOTICE
Never drop the water temperature sensor, espe-
cially on a hard surface. Such a shock to the water
temperature sensor can damage it.
• Tighten:
Torque - Water Temperature Sensor: 22 N·m (2.2 kgf·m, 16
ft·lb)
• Fill the engine with coolant and bleed the air from the cool-
ing system (see Coolant Change in the Periodic Mainte-
nance chapter).
Water Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnect
Tilt up the cargo bed.
• the water temperature sensor connector [A].
FUEL SYSTEM (DFI) 3-61
Water Temperature Sensor (Service Code 14)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.
1. ECU
2. Water Temperature Sensor
3-62 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24)
Speed Sensor Removal
NOTICE
Never drop the speed sensor, especially on a hard
surface. Such a shock to the speed sensor can
damage it.
• Tighten:
Torque - Speed Sensor Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Connections:
Digital Meter (+) → BR lead of Main Harness
Digital Meter (–) → BK lead of Main Harness
• Turn
age.
the ignition switch ON and measure the input volt-
• Turn
age.
the ignition switch ON and measure the output volt-
1. ECU
2. Speed Sensor
3. Power Source
FUEL SYSTEM (DFI) 3-65
Ignition Coils #1, #2 (Service Code 51, 52)
Ignition Coil #1: Service Code 51
Ignition Coil #2: Service Code 52
Ignition Coil Removal/Installation
• Refer to the Ignition Coil Removal and Installation in the
Electrical System chapter.
Ignition Coil Primary Winding Resistance
Inspection
• Refer to the Ignition Coil Inspection in the Electrical Sys-
tem chapter.
If the reading is within the standard, check the input volt-
age (see Ignition Coil Input Voltage Inspection).
Ignition Coil Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
•○Do not disconnect
Remove the ECU (see ECU Removal).
the ECU connectors.
• Connect a digital meter [A] to the connector [B] with the
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
1. Ignition Switch
2. ECU
3. Engine Ground Terminal
4. Battery
5. Fuse Box 1
6. Main Fuse 30 A
7. Ignition Coil #1
8. Ignition Coil #2
FUEL SYSTEM (DFI) 3-67
DFI Warning Indicator Light
DFI Warning Indicator Light Inspection
○The DFI warning indicator light [A] blinks by the data sent
from the ECU.
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
[C] KAF620MD ∼/PD ∼
•Turn the ignition switch ON.
○The DFI warning indicator light should go on for two sec-
onds.
If the light does not go on, replace the bulb (see Indicator
Light Bulb Replacement in the Electrical System chapter)
or check the input voltage.
• Remove:
Battery (Battery Removal in the Electrical System chap-
ter)
ECU Mounting Bolts [A]
ECU [B]
ECU Connector [C]
ECU Installation
• Install:
ECU Connector
ECU
• Tighten:
Torque - ECU Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Install the removed parts.
ECU Power Supply Inspection
• Remove:
Battery (Battery Removal in the Electrical System chap-
ter)
• Remove the ECU from the frame.
• Visually inspect the ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.
1. Ignition Switch
2. ECU Relay
3. ECU
4. Battery
5. Fuse Box 1
6. Main Fuse 30 A
7. ECU Relay Fuse 10 A
3-72 FUEL SYSTEM (DFI)
DFI Power Source
ECU Relay Fuse Removal
• Refer
ter.
to the Fuse Removal in the Electrical System chap-
Testing Relay
Digital Meter Range: × 1 Ω
Criteria: When battery is connected →0 Ω
When battery is disconnected →∞ Ω
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
If the relay does not work as specified, replace the relay.
FUEL SYSTEM (DFI) 3-73
Fuel Line
Fuel Pressure Inspection
NOTE
○Be sure the battery is fully charged.
• Tilt up the seat and cargo bed.
• Fuel Hose (see Fuel Hose Replacement in the Periodic
Remove:
Maintenance chapter)
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
WARNING
Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death. Do not try to start the engine with the fuel
hoses disconnected.
NOTICE
Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Prepare athe
Wait until engine cools down.
• suitable fuel hose and a measuring cylinder.
• Open
tank.
the fuel tank cap [A] to lower the pressure in the
• Disconnect the fuel hose from the fuel pump (see Fuel
Tank Removal).
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
FUEL SYSTEM (DFI) 3-75
Fuel Line
• Connect the prepared fuel hose [A] to the fuel outlet pipe.
• Insert the fuelfuelhose
Secure the hose with a clamp.
• into the measuring cylinder [B].
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
NOTICE
Do not drive the fuel pump 3 seconds or more with-
out the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
NOTICE
Never drop the fuel pump, especially on a hard sur-
face. Such a shock to the pump can damage it.
• Remove:
Fuel Pump Lead Connector [A]
• ment in the Periodic
Disconnect the fuel hose [B] (see Fuel Hoses Replace-
Maintenance chapter).
• Fuel Pump Mounting Bolts [C]
Remove:
Plate [D]
Fuel Pump [E]
[F] KAF620M9 ∼ MC/N9/P9 ∼ PC
[G] KAF620MD ∼/PD ∼
• Install the fuel pump [A] and plate [B], so that the projec-
tions [C] fit into the recesses.
[D] KAF620M9 ∼ MC/N9/P9 ∼ PC
[E] KAF620MD ∼/PD ∼
• Tighten:
Torque - Fuel Pump Mounting Bolts: 4.0 N·m (0.41 kgf·m,
35 in·lb)
• Turn the ignition switch ON and make sure that the fuel
pump operates (make light sounds) for 3 seconds, and
then stops.
• Turn the ignition switch OFF.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
3-78 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Operating Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Disconnect
Tilt up the seat.
• the measuringthe fuel pump lead connector and connect
adapter [A] between these connectors as
shown in the figure.
Main Harness [B]
Fuel Pump [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect
leads.
a digital meter [D] to the measuring adapter
• Remove:
Cover [A]
Fuel Filter [B]
• Check the fuel filter of the visible damage.
If the fuel filter is damaged, replace it with a new one.
• Wash the fuel filter in non-flammable of high flash-point
solvent. Use a soft brush to remove any contaminants
trapped the fuel filter.
3-80 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Relay Removal
NOTICE
Never drop the relay, especially on a hard surface.
Such a shock to the relay can damage it.
Testing Relay
Digital Meter Range: × 1 Ω
Criteria: When battery is connected →0 Ω
When battery is disconnected →∞ Ω
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
If the relay does not work as specified, replace the relay.
FUEL SYSTEM (DFI) 3-81
Fuel Pump
Fuel Pump Circuit (KAF620M9 ∼ MC/N9/P9 ∼ PC)
• Pull the injector joint [A] toward the exhaust pipe and pull
up the fuel injectors [B].
NOTE
○Take care not to damage the injector inserts when they
are pulled from the inlet manifold [C].
• Replace the seal [A] and O-ring [B] with new ones.
• Install the fuel injector [C] and insert the projections [D]
into the holes [E] in the inlet manifold.
• Install the fuel pipe and tighten the bolt.
• Install the removed parts.
3-84 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Audible Inspection
NOTE
○Be sure the battery is fully charged.
• Start the engine, and let it idle.
• Put thethegriptipend
Apply of a screwdriver [A] to the fuel injector [B].
onto your ear, and listen whether the fuel
injector is clicking or not.
○A sound scope [C] can also be used.
○The click interval becomes shorter as the engine speed
rises.
• Do the same for the other fuel injectors.
If all the fuel injectors click at a regular intervals, the fuel
injectors are normal.
• Turn the ignition switch OFF.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
• Measure
stopped.
the power source voltage with the engine
1. Ignition Switch
2. ECU Relay
3. ECU
4. Fuel Injector #1
5. Fuel Injector #2
6. Battery
7. Fuse Box 1
8. Main Fuse 30 A
9. ECU Relay Fuse 10 A
3-88 FUEL SYSTEM (DFI)
Throttle Pedal and Cable
Throttle Pedal Free Play Inspection
• Refer to the Throttle Pedal Free Play Inspection in the
Periodic Maintenance chapter.
Throttle Pedal Free Play Adjustment
• Refer to the Throttle Pedal Free Play Adjustment in the
Periodic Maintenance chapter.
Full Throttle Pedal Position Adjustment
• Refer to the Full Throttle Pedal Position Adjustment in the
Periodic Maintenance chapter.
Throttle Cable Installation
• Run the throttle cable correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
• Adjust:
Throttle Pedal Free Play Adjustment (see Throttle Pedal
Free Play Adjustment in the Periodic Maintenance chap-
ter)
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.
• Unhook the hook [A] from the throttle link rod [B] and re-
move the rod from throttle lever [C].
• Remove:
Throttle Cable End [D]
Inlet Air Pressure Sensor Connector [E]
Bolts [F]
Control Panel [G]
• Remove:
Control Panel (see Control Panel Removal)
Spring [D]
Throttle Lever Mounting Nut
Washers
Throttle Lever [E]
Washer
Control Panel
3-90 FUEL SYSTEM (DFI)
Control Panel
• When removing the ball bearing [A], use a press and dis-
card the bearing.
NOTICE
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the body assy can
damage it.
• Remove:
Control Panel Assembly (see Control Panel Assembly
Removal)
• Disconnect the fuel hose [A] (see Fuel Hoses Replace-
ment in the Periodic Maintenance chapter).
• Remove:
Main Throttle Sensor Connector [B]
Subthrottle Sensor Connector [C]
Subthrottle Valve Actuator Connector [D]
Fuel Injector Connectors [E]
3-92 FUEL SYSTEM (DFI)
Throttle Body Assy
• Remove:
Water Hose Bracket Bolt [A]
• Loosen the clamp screw [A] and remove the air duct [B].
• Breather Hose [C] (KAF620M9 ∼ MD/N9/P9 ∼ PD)
Disconnect:
• Remove:
Air Temperature Sensor Connector [D]
Inlet Pipe Nuts [E]
Bracket [F]
• Lift up the inlet manifold [A], and remove the inlet pipe [B]
and throttle body assy [C].
• Install:
New Gaskets
Inlet Manifold [A]
• Tighten the inlet manifold bolts following the tightening
sequence.
Throttle Body Side [B]
Maintenance chapter)
Throttle Pedal Free Play (see Throttle Pedal Free Play
Inspection in the Periodic Maintenance chapter)
• Adjust the position of the stop screw [A] until the lower of
two voltage readings meets below Main Throttle Sensor
Output Voltage Specification.
Main Throttle Sensor Output Voltage
Specification: 1.01 ±0.02 V
Example:
Reading 1 voltage = 1.02 V
Reading 2 voltage = 0.90 V
○As the Reading 2 is lower than Reading 1, adjust the stop
screw position so that the Reading 2 becomes 1.01 ±0.02
V.
• Once the stop screw is properly adjusted, tighten the lock-
nut [B].
NOTE
○Hold the stop screw when tightening the locknut.
• Re-measure the output voltages again to verify the volt-
age readings are within the specifications.
• Remove
connector.
the measuring adapter and reconnect the sensor
• Adjust the stop screw until the main throttle valve [A] is the
specified position using a pin gauge of 0.37 mm (0.0146
in.).
• Once
nut.
the stop screw is properly adjusted, tighten the lock-
NOTE
○Hold the stop screw when tightening the locknut.
• Install:
Inlet Pipe (see Throttle Body Assy Installation)
3-96 FUEL SYSTEM (DFI)
Inlet Manifold
Inlet Manifold Removal
• Turn the ignition switch OFF.
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Control Panel Assembly (see Control Panel Assembly
Removal)
Fuel Injectors (see Fuel Injector Removal)
Throttle Body Assy (see Throttle Body Assy Removal)
Water Temperature Sensor Connector [A]
Band [B]
Inlet Manifold [C]
Inlet Manifold Installation
• Refer to the Throttle Body Assy Installation for the inlet
manifold installation.
• Install the removed parts.
FUEL SYSTEM (DFI) 3-97
Air Cleaner
Air Cleaner Element Cleaning
• Refer to the Air Cleaner Element Cleaning in the Periodic
Maintenance chapter.
Air Cleaner Housing Removal
• Remove:
Air Ducts [A]
Air Cleaner Housing Bolts [B]
Air Cleaner Housing [C]
• Remove:
Mounting Rivets [A]
Screws [B]
• Disconnect:
Fuel Hose [A] (see Fuel Hoses Replacement in the Pe-
riodic Maintenance chapter)
Fuel Pump Lead Connector [B]
• Remove:
Fuel Tank Mounting Bolt, Washer and Nut [C]
• Remove:
Fuel Tank Mounting Bolt [A] and Washer
• Remove:
Fuel Tank Mounting Bolt [A] and Washer
Fuel Tank [B]
FUEL SYSTEM (DFI) 3-99
Fuel Tank
Fuel Tank Installation
If the rubber dampers [A] were removed, install them onto
the fuel tank with an adhesive.
[B] KAF620M9/N9/P9, MA/PA
[C] KAF620MB ∼/PB ∼
KAF620M9 ∼ MC/N9/P9 ∼ PC
•Install the check valve [A] so that the arrow [B] faces the
fuel tank.
Black Color [C]
Blue Color [D]
•Install the clamps [E].
•Connect the fuel pump lead connector.
•Install the removed parts.
3-100 FUEL SYSTEM (DFI)
Fuel Tank
For KAF620MD ∼/PD ∼
•Install the check valve [A] so that the orange color side
[B] faces the fuel tank.
•Install the clamps [C].
•Connect the fuel pump lead connector.
•Install the removed parts.
• Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
• Pour the solvent out of the tank.
• Visually tank
Dry the with compressed air.
• Fuel Tank Cap the
inspect following for any damage.
Gasket
Fuel Level Gauge (KAF620M9 ∼ MC/N9/P9 ∼ PC)
• Replace them if they are damaged.
○Push down the gasket [A] into the bottom of the fuel tank
cap [B], and insert the flange portions [C] of the gasket to
the cap threads.
• Install the fuel level gauge so that the 1/2 scale [A] faces
the left [B] of the vehicle.
• Push the new gauge cap over the gauge so that the notch
[C] aligns with the 1/2 scale.
• Check that the gauge cap nails fit securely in the grooves
in the fuel tank boss.
Fuel Level Gauge Check (KAF620M9 ∼ MC/N9/P9
∼ PC)
• Remove the fuel level gauge from the fuel tank (see Fuel
Level Gauge Removal).
• Check that the float [A] moves up and down [B] smoothly
without binding. It should go down under its own weight.
If the float does not move smoothly or has visual damage,
replace the gauge.
3-102 FUEL SYSTEM (DFI)
Evaporative Emission Control System (CAL Model and KAF620MB ∼/PB ∼)
NOTICE
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
1. Check Valve
2. Fuel Tank
3. Fuel Filter
4. Band (for Canister)
5. Canister
6. Breather Hose (Canister ∼ Fuel Filter)
7. Fuel Tank Hose (Canister ∼ Fuel Tank)
8. Purge Hose (Canister ∼ Inlet Pipe)
9. Bracket (for Canister)
10. Inlet Pipe
11. KAF620MB ∼ MC/PB ∼ PC
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................ 4-2
Specifications ......................................................................................................................... 4-4
Sealant ................................................................................................................................... 4-5
Coolant Flow Chart................................................................................................................. 4-6
Coolant ................................................................................................................................... 4-8
Coolant Level Inspection................................................................................................... 4-8 4
Coolant Draining ............................................................................................................... 4-8
Coolant Filling ................................................................................................................... 4-8
Coolant Reserve Tank Removal ....................................................................................... 4-8
Coolant Reserve Tank Installation .................................................................................... 4-9
Pressure Testing ............................................................................................................... 4-9
Water Pump............................................................................................................................ 4-10
Water Pump Removal ....................................................................................................... 4-10
Water Pump Installation .................................................................................................... 4-11
Water Pump Inspection..................................................................................................... 4-12
Radiator and Radiator Fan ..................................................................................................... 4-13
Radiator Removal ............................................................................................................. 4-13
Radiator Installation ......................................................................................................... 4-14
Radiator Inspection ........................................................................................................... 4-14
Radiator Cleaning ............................................................................................................. 4-14
Radiator Cap .......................................................................................................................... 4-15
Radiator Cap Inspection ................................................................................................... 4-15
Thermostat ............................................................................................................................. 4-16
Thermostat Removal......................................................................................................... 4-16
Thermostat Installation...................................................................................................... 4-16
Thermostat Inspection ...................................................................................................... 4-16
Hoses and Pipes ................................................................................................................... 4-18
Hose and Pipe Installation ................................................................................................ 4-18
Hose Inspection ................................................................................................................ 4-18
Water Temperature Sensor .................................................................................................... 4-19
Water Temperature Sensor Removal................................................................................ 4-19
Water Temperature Sensor Installation............................................................................. 4-19
Water Temperature Sensor Inspection ............................................................................. 4-19
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Coolant Drain Plugs 17 1.7 13
2 Coolant Reservoir Mounting Bolt 4.4 0.45 39 in·lb
3 Radiator Fan Mounting Bolts 4.9 0.50 43 in·lb
4 Radiator Mounting Bolts 8.8 0.90 78 in·lb
5 Radiator Screen Bolts 8.8 0.90 78 in·lb
6 Water Pipe Bolts 8.8 0.90 78 in·lb
7 Water Pump Cover Bolt (M8) 25 2.5 18 S
8 Water Pump Cover Bolts (M6) 8.8 0.90 78 in·lb S
9 Water Pump Housing Bolt 8.8 0.90 78 in·lb
10. KAF620M9 ∼ MD/N9/P9 ∼ PD
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
4-4 COOLING SYSTEM
Specifications
NOTICE
Do not check the level through the coolant filler by
removing the radiator cap. If the cap is removed,
the coolant will flow out from the reservoir tank.
Coolant Draining
• Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Filling
• Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Reserve Tank Removal
• Tilt up the front cargo hood.
• Quick Rivets [A]
Remove:
Pressure Testing
• Remove the radiator cap, and install a cooling system
pressure tester [A] and adapter [B] on the radiator filler
neck [C].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leakage.
• Remove:
Water Pump Housing Bolt [A]
Water Pump Housing [B]
• Remove:
Water Pump Drive Gear [A]
• Remove:
Pin [A]
Washer [B]
• Remove:
Water Pump Impeller [A]
Shaft [B]
Pin [C] and O-ring [D]
COOLING SYSTEM 4-11
Water Pump
• Remove:
Mechanical Seal [A]
Oil Seal [B]
• Fit the washer tab [A] to the notch [B] of the housing.
• the drive gear notches [C] to the pin [D].
Fit
• Measure
bearing.
the inside diameter [A] of the water pump shaft
If the bearing has worn past the service limit, replace the
crankcase with a new one.
Water Pump Shaft Bearing Inside Diameter
Standard: 10.020 ∼ 10.058 mm (0.3945 ∼ 0.3960 in.)
Service Limit: 10.09 mm (0.397 in.)
COOLING SYSTEM 4-13
Radiator and Radiator Fan
Radiator Removal
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Front Cover (see Front Cover Removal in the Frame
chapter)
Fan Motor Lead Connectors [A]
• Disconnect:
Water Hoses [A]
• Disconnect:
Water Hose [A]
• Remove:
Radiator Mounting Bolts [A]
Radiator [B]
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
• Remove:
Radiator Fan Mounting Bolts [A]
Radiator Fan Assembly [B]
4-14 COOLING SYSTEM
Radiator and Radiator Fan
Radiator Installation
• Install the removed parts in reverse order.
• Tighten:
Torque - Radiator Fan Mounting Bolts: 4.9 N·m (0.50 kgf·m,
43 in·lb)
Radiator Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
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 with a new one.
Radiator Cleaning
• Refer to the Radiator Cleaning in the Periodic Mainte-
nance chapter.
COOLING SYSTEM 4-15
Radiator Cap
Radiator Cap Inspection
• Check
[B].
the radiator cap valve seals [A] and valve spring
• Remove:
Thermostat Housing Cap Bolts [A]
Thermostat Housing Cap [B]
Thermostat Installation
• Install
top.
the thermostat [A] so that the jiggle valve [B] is on
nance chapter)
Thermostat Inspection
• Remove the thermostat, and inspect the thermostat valve
[A] at room temperature.
If the valve is open, replace the valve with a new one.
COOLING SYSTEM 4-17
Thermostat
Hose Inspection
• 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 any damaged hoses.
COOLING SYSTEM 4-19
Water Temperature Sensor
Water Temperature Sensor Removal
• Refer to the Water Temperature Sensor Removal in the
Fuel System (DFI) chapter.
Water Temperature Sensor Installation
• Refer to the Water Temperature Sensor Installation in the
Fuel System (DFI) chapter.
Water Temperature Sensor Inspection
• Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
ENGINE TOP END 5-1
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Valve Adjusting Screw Locknuts 9.8 1.0 87 in·lb
2 Cylinder Head Bolts 22 2.2 16 S
3 Cylinder Head Plug 22 2.2 16
4 Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb
5 Exhaust Pipe Holder Nuts 8.8 0.90 78 in·lb
6 Muffler Mounting Bolts 19.6 2.0 14
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
5-4 ENGINE TOP END
Specifications
Valves
Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 32° - 33:
57001-1116 57001-1199
• Remove:
Spark Plug Cap [A]
Cylinder Head Cover Bolts [B]
Cylinder Head Cover [C]
• Remove:
Spark Plug
Cylinder Head Bolts [A]
Cylinder Head [B]
Cylinder Head Gasket
Rocker Arm Push Rods
5-8 ENGINE TOP END
Cylinder Head
Cylinder Head Installation
• Clean the mating surface of the cylinder head and the
cylinder.
• Replace the gasket [A] with a new one.
• place on the
Check to see that the cylinder head knock pins [B] are in
cylinder.
• Apply
rod.
engine oil to the both ends and shaft of the push
• Remove:
Split Keepers [A]
Valve Spring Retainers [B]
Valve Springs
Valves
○Press down the valve spring retainer holding the valve
head, and remove the split keepers.
• Remove:
Oil Seals [A]
Spring Seats [B]
○Valve guides are not replaceable, do not remove them.
• Replace the circlip on the rocker shaft with a new one.
• Apply engine oil to the
Apply molybdenum disulfide grease to the valve stem.
• rocker shaft.
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.
60 ............................. Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]
5-12 ENGINE TOP END
Valves
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.
NOTICE
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.
• Lap the valve to the seat, once the seat width and O.D.
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] Lapper
[B] Valve Seat
[C] Valve
•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. If it is, it may have
been refaced too much; replace it.
•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 in the Peri-
odic Maintenance chapter).
ENGINE TOP END 5-13
Valves
Valve Seat Repair
5-14 ENGINE TOP END
Valves
Valve Spring Free Length Inspection
• Measure the valve spring free length.
If the free length is less than the service limit, replace the
valve spring [A] with a new one.
Valve Spring Free Length
Standard: 34.3 mm (1.35 in.)
Service Limit: 32.6 mm (1.28 in.)
• Remove:
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe Clamp Bolts [B] and Nuts
Exhaust Pipes [C]
Muffler Removal
• Remove:
Exhaust Pipe Cover (see Exhaust Pipe Removal)
Exhaust Pipe Clamp Bolts [A] and Nuts
Muffler Mounting Bolts [B]
Muffler [C]
• Tighten:
Torque - Muffler Mounting Bolts: 19.6 N·m (2.0 kgf·m, 16
ft·lb)
• Replace the exhaust pipe gaskets and muffler gaskets
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.
Torque - Exhaust Pipe Holder Nuts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
5-18 ENGINE TOP END
Exhaust Pipe and Muffler
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
clamp.
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 clamp.
• 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
• Refer to the Spark Arrester Cleaning in the Periodic Main-
tenance chapter.
CONVERTER SYSTEM 6-1
Converter System
Table of Contents
Exploded View........................................................................................................................ 6-2
Specifications ......................................................................................................................... 6-6
Special Tools .......................................................................................................................... 6-7
Air Cleaner.............................................................................................................................. 6-8
Air Cleaner Housing Removal........................................................................................... 6-8
Air Cleaner Housing Installation........................................................................................ 6-9
Air Cleaner Element Removal........................................................................................... 6-10
Air Cleaner Element Cleaning/Inspection ......................................................................... 6-10
Torque Converter.................................................................................................................... 6-11
Torque Converter Cover Removal .................................................................................... 6-11
Torque Converter Cover Installation ................................................................................. 6-11
6
Torque Converter Case Removal...................................................................................... 6-12
Torque Converter Case Installation................................................................................... 6-12
Torque Converter Case Disassembly ............................................................................... 6-13
Torque Converter Case Assembly .................................................................................... 6-13
Drive Belt ................................................................................................................................ 6-14
Drive Belt Removal ........................................................................................................... 6-14
Drive Belt Installation ........................................................................................................ 6-14
Drive Belt Inspection ......................................................................................................... 6-14
Drive Belt Deflection Inspection ........................................................................................ 6-14
Drive Belt Deflection Adjustment ...................................................................................... 6-14
Drive Pulley ............................................................................................................................ 6-15
Drive Pulley Removal........................................................................................................ 6-15
Drive Pulley Disassembly ................................................................................................. 6-15
Drive Pulley Assembly ...................................................................................................... 6-16
Spider/Wear Guide Clearance Inspection......................................................................... 6-18
Drive Pulley Inspection ..................................................................................................... 6-18
Bushing Installation........................................................................................................... 6-20
Drive Pulley Installation..................................................................................................... 6-20
Driven Pulley .......................................................................................................................... 6-22
Driven Pulley Removal...................................................................................................... 6-22
Driven Pulley Disassembly ............................................................................................... 6-22
Driven Pulley Assembly .................................................................................................... 6-23
Driven Pulley Inspection ................................................................................................... 6-24
Bushing Installation........................................................................................................... 6-25
Driven Pulley Installation................................................................................................... 6-25
6-2 CONVERTER SYSTEM
Exploded View
CONVERTER SYSTEM 6-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Drive Pulley Bolt 76 7.7 56 R
2 Drive Pulley Cover Bolts 12.5 1.3 111 in·lb
3 Driven Pulley Bolt 93 9.5 69 L
4 Wear Shoe Screws 1.1 0.11 9.7 in·lb L
5 Ramp Weight Nuts 6.9 0.70 61 in·lb R
6 Spider 275 28.0 203
L: Apply a non-permanent locking agent.
R: Replacement Parts
6-4 CONVERTER SYSTEM
Exploded View
CONVERTER SYSTEM 6-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Air Cleaner Housing Bolts 16 1.6 12
2 Air Cleaner Housing Bolts 20 2.0 15
3 Converter Case Bolts 20 2.0 15
Converter Cover Bolts (Converter Cover without
7.0 0.71 62 in·lb
Collars)
4
Converter Cover Bolts (Converter Cover with
8.8 0.90 78 in·lb
Collars)
5 Cooling Fan Cover Bolts 8.8 0.90 78 in·lb
6 Heat Guard Plate Bolts 8.8 0.90 78 in·lb
7. KAF620M9/N9/P9 and KAF620MA/PA Early Models
R: Replacement Parts
6-6 CONVERTER SYSTEM
Specifications
• Remove:
Air Cleaner Housing Bolts [A], Washers and Nuts
Air Cleaner Housing [B]
[C] KAF620M9/N9/P9 and KAF620MA/PA early models
[D] KAF620MA/PA late models and KAF620MB ∼/PB ∼
• Tighten
duct.
the clamp [L] to the bare position from the end of
6-10 CONVERTER SYSTEM
Air Cleaner
Air Cleaner Element Removal
For KAF620M9/N9/P9 and KAF620MA/PA Early Models
•Remove:
Wingbolts [A]
Cap [B]
• Remove:
Air Cleaner Element [A]
• After removing the element, stuff pieces of lint-free, clean
cloth into the air cleaner duct to keep dirt out of the torque
converter.
NOTICE
If dirt gets into the torque converter, excessive wear
and loss of driving power may result.
• Remove:
Converter Cover Bolts
Heat Guard Plate [A]
• Remove:
Torque Converter Cover [A]
• Install:
Torque Converter Case [A]
Converter Case Bolt (L = 45 mm (1.77 in.)) [B] and
Washer
Converter Case Bolts (L = 25 mm (0.98 in.)) [C] and
Washers
• Tighten:
Torque - Converter Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
• Remove:
Screws [A]
Heat Guard Plate [B]
• 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
• Remove:
Spring [A]
6-16 CONVERTER SYSTEM
Drive Pulley
• Put the drive pulley wrench [A] on the spider [B] as shown,
and remove the spider with the movable sheave [C] from
the fixed sheave [D].
Special Tool - Drive Pulley Wrench: 57001-1411
• Remove:
Spider [A]
Spacer [B]
Wear Guides [C]
Pins [D] (Use a hand press.)
Rollers [E]
Nuts [F]
Ramp Weight Pin [G]
Ramp Weight [H]
• Install:
Roller [A]
Spacers [B]
Pin [C]
○Press in the pin as shown, so that the pin end is flush [D]
with the end of the hole.
[E] Spider
[F] Chamfer
•Check the rollers turn freely.
CONVERTER SYSTEM 6-17
Drive Pulley
○Hold the fixed sheave [A] with the drive & driven pulley
holder [B] in a vise.
Spacer [B]
Spider [C] and Wear Guides [D]
○Align the arrow [E] on the spider with the boss [F] on the
movable sheave.
○Insert the guides so that the rubber side (small diameter)
faces inward.
• Tighten:
Special Tool - Drive Pulley Wrench [A]: 57001-1411
Torque - Spider: 275 N·m (28.0 kgf·m, 203 ft·lb)
• Hold the drive pulley with the drive pulley holder [A].
Special Tool - Drive Pulley Holder: 57001-1548
• Tighten:
Torque - Drive Pulley Bolt [B] (New): 76 N·m (7.7 kgf·m, 56
ft·lb)
CONVERTER SYSTEM 6-21
Drive Pulley
• Install:
Cooling Fan Cover
Cooling Fan Cover Bolts
• Tighten:
Torque - Cooling Fan Cover Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
6-22 CONVERTER SYSTEM
Driven Pulley
Driven Pulley Removal
• Remove:
Drive Pulley (see Drive Pulley Removal)
Drive Belt (see Drive Belt Removal)
• Using the flywheel & pulley holder [A] and attachments
[B], remove the driven pulley bolt [C].
Special Tools - Flywheel & Pulley Holder: 57001-1605
Pulley Holder Attachment: 57001-1472
• Remove:
Driven Pulley
Driven Pulley Disassembly
• Hold the driven pulley [A] with the drive & driven pulley
holder and driven pulley holder in a vise.
Special Tools - Drive & Driven Pulley Holder: 57001-1412
Driven Pulley Holder: 57001-1465
○Install:
Base Plate [B]
Stopper Pins [C]
Guide Pin [D]
Stud Bolt [E]
Adapter [F], bolts [G] and Nuts [H]
Flange Nut [I]
• Confirm the length [J] is 36 mm (1.4 in.).
• Turn the flange nut [A] clockwise and remove the circlip
[B] with the inside circlip pliers.
Special Tool - Outside Circlip Pliers: 57001-144
• Remove:
Circlip [A]
Spacer [B]
Ramp [C]
Spring [D]
Movable Sheave [E]
Spacers [F]
Fixed Sheave [G]
• Remove:
Wear Shoe Screws [A]
Wear Shoes [B]
• Apply
screws.
a non-permanent locking agent to the wear shoe
• Tighten:
Torque - Wear Shoe Screws: 1.1 N·m (0.11 kgf·m, 9.7 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
Driven Pulley Holder: 57001-1465
• Install the spacers [A] on the fixed sheave [B] (see Drive
Belt Deflection Adjustment in the Periodic Maintenance
chapter).
• When installing a new belt, install a spacer of thickness 1
mm (0.039 in.) and any one of the other spacers.
6-24 CONVERTER SYSTEM
Driven Pulley
• Install:
Movable Sheave [A]
Spring [B]
○Insert the spring end into the hole “C”.
NOTE
○The fixed/movable sheave assembly has several differ-
ent spring locations which affect shifting characteristics
of the torque converter.
Bushing Installation
• Press the movable sheave bushings [A] into the movable
sheave [B] with a suitable driver until the end of the bush-
ing is even with the end [C] of the hole.
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Oil Pressure Switch 9.8 1.0 87 in·lb SS
2 Engine Oil Drain Plug (M16) 22 2.2 16
3 Engine Oil Drain Plug (M14) 32 3.3 24
4 Crankcase Cover Bolts 25 2.5 18
5 Oil Filter 17.6 1.8 13 EO
6 Oil Filler Pipe Bolts 4.4 0.45 39 in·lb
7 Oil Filter Stud Bolt 27 2.8 20
8 Dipstick Pipe Bolt (KAF620ME/PE) 8.8 0.9 78 in·lb
9. KAF620M9 ∼ MB/N9/P9 ∼ PB
10. KAF620M9 ∼ MD/N9/P9 ∼ PD
EO: Apply engine oil.
G: Apply grease.
R: Replacement Parts
SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).
7-4 ENGINE LUBRICATION SYSTEM
Specifications
1. Oil Screen
2. Oil Pump
3. Relief Valve
4. Oil Filter
5. Oil Pressure Switch
6. Crankshaft
7. Camshaft
8. Rocker Arm
ENGINE LUBRICATION SYSTEM 7-7
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
• Apply engine oil to the rubber seal lip [A] on the dipstick.
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
• Align the groove [A] on the dipstick with the mark [B] on
the dipstick pipe.
NOTICE
Do not insert the dipstick except the specified di-
rection. This can damage the plate of the dipstick
gauge.
• Pull out the dipstick and check the oil level. The oil level
should be between the “F” (Full) and “L” (Low) range (grid
area) [A] on the dipstick.
If the oil level is too high, remove the excess oil, using
a syringe or some other suitable device, 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. Then at
your earliest convenience, change the oil completely.
Engine Oil Change
• Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.
Oil Filter Removal
• Refer to the Oil Filter Removal in the Periodic Mainte-
nance chapter.
Oil Filter Installation
• Refer to the Oil Filter Installation in the Periodic Mainte-
nance chapter.
ENGINE LUBRICATION SYSTEM 7-9
Oil Pump and Relief Valve
Oil Pump and Relief Valve Removal
• Remove:
Crankcase Cover (see Crankcase Cover Removal in the
Engine Bottom End chapter)
Oil Pump Cover Bolts [A]
Oil Pump Gear [B] and Oil Pump Cover [C]
Oil Pump Inner Rotor [D]
Oil Pump Outer Rotor [E]
Relief Valve Spring [F]
Steel Ball [G]
• Install
[B].
the pump shaft with its pin [A] in the inner rotor slot
• Install the oil pump cover [C] so that the cover stops the
relief valve spring [D].
• Fill the oil pump with engine oil for initial lubrication.
Oil Pump and Relief Valve Inspection
• Visually inspect the oil pump gear, shaft, inner rotor [A],
outer rotor [B], and rotor housing [C] in the crankcase.
If there is any damage or uneven wear, replace them.
7-10 ENGINE LUBRICATION SYSTEM
Oil Pump and Relief Valve
• Visually
[B].
inspect the relief valve spring [A], and steel ball
• Measure
parts.
the following diameters and width of the oil pump
If the part(s) has worn past the service limit, replace the
worn part(s).
Inner Rotor Shaft Diameter [A]
Standard: 10.973 ∼ 10.984 mm (0.4320 ∼ 0.4324 in.)
Service Limit: 10.923 mm (0.4300 in.)
• Remove:
Oil Screen [A]
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................ 8-2
Engine Removal/Installation ................................................................................................... 8-4
Engine Removal................................................................................................................ 8-4
Engine Installation............................................................................................................. 8-6
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Engine Mounting Bolts 44 4.5 32
2 Engine Positioning Plate Bolts 20 2.0 15
8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
• Disconnect:
Battery Terminal Cables (see Battery Removal in the
Electrical System chapter)
• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
• Remove:
Cargo Bed (see Cargo Bed Removal in the Frame chap-
ter)
Exhaust Pipes (see Exhaust Pipe Removal in the Engine
Top End chapter)
Torque Converter Case (see Torque Converter Case Re-
moval in the Converter System chapter)
Inlet Manifold (see Throttle Body Assy Removal in the
Fuel System (DFI) chapter)
• Remove:
Oil Filler Pipe Bolts [A]
• Disconnect:
Crankshaft Sensor Lead Connector [A]
Alternator Lead Connector [B]
Ignition Coil Lead/Oil Pressure Switch Lead/Starter Mo-
tor Lead Connector [C]
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
• Disconnect:
Water Hose [A]
• Remove:
Forward/Reverse Shift Shaft Lever [B]
Hi/Low Shift Shaft Lever [C] (KAF620M/N)
Bolts [D], Nuts [E] and Collar [F]
Cable Bracket [G]
• Remove:
Ignition Coil Lead Connectors [A]
Starter Motor Lead Connector [B]
Starter Motor Cable [C]
Engine Ground Terminal [D]
• Remove:
Bolts [A]
Dipstick Pipe [B]
• Disconnect:
Water Hose [C]
• Remove:
Engine Mounting Bolts [A]
Engine
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Installation
• Adjust the engine mounting position for alignment of the
torque converter.
○Mount the engine and install the engine mounting bolts
loosely.
○Install the engine positioning plate [A] onto the transmis-
sion case and crankcase as shown.
○Tighten the bolts [B] [C] until the plate is fitted to the en-
gine completely.
NOTE
○Use the bolt [C] of the torque converter case temporar-
ily.
○Tighten:
Torque - Engine Positioning Plate Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Engine Mounting Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)
○Remove the torque converter case bolt [C].
• Adjust:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
ENGINE BOTTOM END 9-1
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Connecting Rod Big End Cap Bolts 21 2.1 15 EO
2 Coolant Drain Plugs 17 1.7 13
3 Crankcase Cover Bolts 22 2.2 16
4 Oil Filter Stud Bolt 27 2.8 20
5 Dipstick Pipe Bolt (KAF620ME/PE) 8.8 0.9 78 in·lb
6. KAF620M9 ∼ MB/N9/P9 ∼ PB
7. KAF620M9 ∼ MD/N9/P9 ∼ PD
EO: Apply engine oil.
G: Apply grease.
R: Replacement Parts
9-4 ENGINE BOTTOM END
Specifications
Camshaft Inspection
• Check the camshaft gear [A] for worn or broken teeth.
If excessively worn or broken teeth are observed, replace
the camshaft.
• Push the connecting rod ends into the cylinders, and pull
the pistons and connecting rods out of the cylinders.
NOTICE
Note a location of the arrow on the top of the piston
in relation to MADE IN JAPAN on the connecting
rod. No.1 cylinder piston is opposite of No.2 piston.
Keep parts together as a set.
[A] Arrow
[B] Alternator
[C] Large Chamfer
[D] Raised Letter (MADE IN JAPAN)
• Remove one of the piston pin snap rings [A] with needle
nose pliers.
• Remove the piston by pushing the piston pin out the side
from which the snap ring was removed. Use the piston
pin puller assembly [A] and adapter "C" [B] if the pin is
tight.
Special Tool - Piston Pin Puller Assembly: 57001-910
9-10 ENGINE BOTTOM END
Cylinders and Pistons
Piston Installation
• Apply engine oil:
Piston Pin
Piston Skirt
Cylinder Bore
•Oil Ring Installation:
○First install the expander in the piston oil ring groove so
that the expander ends [A] butt together. Be sure that the
expander end rail [B] is inserted into the expander holes.
○Install the upper and lower steel rails. There is no UP or
DOWN to the rails. They can be installed either way.
• Do not mix up the top and second rings. The top and
second rings are not symmetrical and must be installed
with the marked side facing up.
Top Ring [A]
Second Ring [B]
"N" Mark [C]
• Fit a new piston pin snap ring into the side of the piston so
that the ring opening [A] does not coincide with the notch
[B] in the edge of the piston pin hole.
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
• Using the piston ring compressor grip [A] and the belt [B],
insert the piston and connecting rod into the cylinder.
Special Tools - Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt, 67 ∼ 79:
57001-1097
○Insert the piston and connecting rod so that the arrow [C]
on the top of the piston points toward the alternator side.
○Lightly tap the top of the piston with a plastic mallet to
insert the piston and connecting rod into the cylinder.
•Apply engine oil:
Crankpin
Threads of Connecting Rod Big End Cap Bolts
NOTICE
The connecting rod and cap are machined at the
factory in the assembled state, so the connecting
rod and cap must be replaced as a set.
• Tighten:
Torque - Connecting Rod Big End Cap Bolts: 21 N·m (2.1
kgf·m, 15 ft·lb)
9-12 ENGINE BOTTOM END
Cylinders and Pistons
Piston Ring, Piston Ring Groove Wear Inspection
• Check
ing.
for uneven groove wear by inspecting the ring seat-
Crankshaft Cleaning
• After removing, clean the crankshaft with a high flash
-point solvent.
• Blow the crankshaft oil passages [A] with compressed air
to remove any foreign particles or residue that may have
accumulated.
ENGINE BOTTOM END 9-15
Crankshaft and Connecting Rods
Connecting Rod Bend/Twist Inspection
•○Measure the connecting rod bend.
Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.
○Select an arbor [B] of the same diameter as the piston pin
and at least 100 mm (3.937 in.) long, and insert the arbor
through the connecting rod small end.
○On a surface plate, set the big-end arbor on V blocks [C].
○With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
small end arbor above the surface plate over a 100 mm
(3.937 in.) length to determine the amount of connecting
rod bend.
If connecting rod bend exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.15/100 mm (0.0059/3.937 in.)
NOTE
○Do not turn the crankshaft during clearance measure-
ment.
○Remove the connecting rod big end cap, and measure the
plastigauge width [A] to determine the bearing/crankpin
clearance.
Connecting Rod Big End Bearing/Crankpin Clearance
Standard: 0.024 ∼ 0.048 mm (0.0009 ∼ 0.0019 in.)
Service Limit: 0.09 mm (0.0035 in.)
NOTE
○The clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigauge.
If the clearance is within the standard, no connecting rod
replacement is required.
If the clearance is between the standard (maximum) and
the service limit, replace the connecting rod and cap as a
set.
ENGINE BOTTOM END 9-17
Crankshaft and Connecting Rods
If the clearance exceeds the service limit, measure the
diameter [A] of the crankpin.
If the crankpin has worn past the service limit, replace the
crankshaft with a new one.
Crankpin Diameter
Standard: 33.967 ∼ 33.980 mm (1.3373 ∼ 1.3378 in.)
Service Limit: 33.95 mm (1.337 in.)
The connecting rod big end inside diameter can be mea-
sured as following.
• Install the connecting rod big end cap and tighten the big
end cap bolts to the specified torque.
Torque - Connecting Rod Big End Cap Bolts : 21 N·m (2.1
kgf·m, 15 ft·lb)
• Measure
end.
the inside diameter [A] of the connecting rod big
If the connecting rod big end bore has worn past the ser-
vice limit, replace the connecting rod and cap as a set.
Connecting Rod Big End Inside Diameter
Standard: 34.004 ∼ 34.015 mm (1.3387 ∼ 1.3392 in.)
Service Limit: 34.04 mm (1.340 in.)
• Measure
bearing.
the inside diameter [A] of the crankshaft main
If the bearing has worn past the service limit, replace the
crankcase bushing and/or crankcase cover with a new
one.
Crankshaft Main Bearing Inside Diameter
Standard:
Bushing 33.997 ∼ 34.064 mm (1.3385 ∼ 1.3411 in.)
Cover 34.025 ∼ 34.041 mm (1.3396 ∼ 1.3402 in.)
Service Limit:
Bushing 34.12 mm (1.343 in.)
Cover 34.10 mm (1.343 in.)
ENGINE BOTTOM END 9-19
Breather Valve
Breather Valve Removal
• Remove:
Alternator and Stator (see Alternator and Stator Re-
moval in the Electrical System chapter)
Breather Cover Bolts [A]
Breather Cover [B]
• Remove:
Breather Valve [A]
• Be sure the drain back hole [A] does not accumulate with
slugges before installing the breather valve.
• Align center of the valve seat with center of the reed valve
and back plate, then tighten the mounting screw.
NOTE
○The mounting screw is a self-tapping one. Be aware
that misthreading or overtightening screw will strip the
female threads and ruin the hole.
Transmission
Table of Contents
Exploded View................................... 10-2 2WD/4WD Shift Cable
Specifications .................................... 10-10 Adjustment ................................ 10-26
Special Tools and Sealant ................. 10-11 2WD/4WD Shift Cable
Transmission Oil ................................ 10-12 Lubrication................................. 10-26
Transmission Oil Level Inspection 10-12 2WD/4WD Shift Cable Inspection 10-27
Transmission Oil Change............. 10-12 2WD/4WD Shift Mechanism
Transmission Case............................ 10-13 Removal ................................... 10-27
Transmission Case Removal ....... 10-13 2WD/4WD Shift Mechanism
Transmission Case Installation ... 10-13 Installation ................................. 10-27
Transmission Case Splitting ........ 10-14 2WD/4WD Shift Mechanism
Transmission Case Assembly...... 10-14 Inspection.................................. 10-29
Transmission and Shift Mechanism .. 10-15 Differential Gears and Shift
Transmission and Hi/Low Shift Mechanism ..................................... 10-30
Cables Installation..................... 10-15 Differential Shift Cable
Shift Lever Position Inspection..... 10-18 Adjustment ................................ 10-30
Shift Lever Position Adjustment ... 10-18 Differential Shift Cable
Transmission Shift Cable Lubrication................................. 10-30
Inspection.................................. 10-19 Differential Shift Cable Inspection 10-30
Transmission Removal ............... 10-19 Differential Shift Mechanism
Transmission Installation ............. 10-20 Removal .................................... 10-30 10
Transmission and Shift Differential Shift Mechanism
Mechanism Inspection .............. 10-20 Installation ................................. 10-31
Hi/Low Gears and Shift Mechanism .. 10-22 Differential Shift Mechanism
Hi/Low Shift Cable Installation ..... 10-22 Inspection.................................. 10-31
Hi/Low Shift Cable Inspection ...... 10-22 Differential Gear Removal............ 10-31
Hi/Low Gear and Shift Mechanism Differential Gear Installation......... 10-32
Removal ................................... 10-22 Differential Gear Inspection ......... 10-33
Hi/Low Gear and Shift Mechanism Bearings and Oil Seal........................ 10-34
Installation ................................ 10-23 Bearing Replacement .................. 10-34
Hi/Low Gear and Shift Mechanism Ball Bearing Inspection ................ 10-34
Inspection.................................. 10-25 Needle Bearing Inspection........... 10-34
2WD/4WD Shift Mechanism Oil Seal Inspection ....................... 10-34
(KAF620M/N).................................. 10-26 Transmission Sectional Figure .......... 10-35
10-2 TRANSMISSION
Exploded View
TRANSMISSION 10-3
Exploded View
1. 2WD/4WD Shift Cable (KAF620M/N)
2. Differential Shift Cable
3. Hi/Low Shift Cable (KAF620M/N)
4. Transmission Shift Cable
5. Cover (KAF620P)
CL: Apply cable lubricant.
G: Apply grease.
R: Replacement Parts
10-4 TRANSMISSION
Exploded View
TRANSMISSION 10-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Differential Gear Housing Bolts 57 5.8 42 L
2 Shift Arm Positioning Bolt 36.5 3.7 27
3 Shift Shaft Lever Clamp Bolts 12 1.2 106 in·lb
4 Shift Shaft Stop Bolts 7.8 0.80 69 in·lb
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
TO: Apply transmission oil.
10-6 TRANSMISSION
Exploded View
TRANSMISSION 10-7
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Bearing Holder 118 12.0 87.0 MO
2 Engine Positioning Plate Bolts 20 2.0 15
3 Hi/Low Gear Case Bolts 20 2.0 15
4 Neutral Switch 15 1.5 11
5 Transmission Case Bolts 8.8 0.90 78 in·lb
6 Transmission Case Mounting Nuts 44.1 4.5 33 R
7 Transmission Oil Drain Plug 15 1.5 11
G: Apply grease.
LG: Apply liquid gasket.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
TO: Apply transmission oil.
10-8 TRANSMISSION
Exploded View
(KAF620P)
TRANSMISSION 10-9
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Engine Positioning Plate Bolts 20 2.0 15
2 Neutral Switch 15 1.5 11
3 Shift Arm Positioning Bolt 36.5 3.7 27
4 Shift Shaft Lever Clamp Bolt 12 1.2 106 in·lb
5 Speed Sensor Bolt 8.8 0.90 78 in·lb
6 Transmission Case Bolts 8.8 0.90 78 in·lb
7 Transmission Oil Drain Plug 15 1.5 11
G: Apply grease.
LG: Apply liquid gasket.
R: Replacement Parts
TO: Apply transmission oil.
10-10 TRANSMISSION
Specifications
• 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.
• Pull out the dipstick and check the oil level. The oil level
should be between the upper (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 Transmission Oil Change in the Periodic Mainte-
nance chapter.
TRANSMISSION 10-13
Transmission Case
Transmission Case Removal
• Drain:
Transmission Oil (see Transmission Oil Change in the
Periodic Maintenance chapter)
• Remove:
Cargo Bed (see Cargo Bed Removal in the Frame chap-
ter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Propeller Shafts (see Propeller Shaft Removal in the Fi-
nal Drive chapter)
Torque Converter Case (see Torque Converter Case Re-
moval in the Converter System chapter)
Rear Drive Shafts and Axles (see Rear Drive Shaft and
Axle Removal in the Final Drive chapter)
• Remove:
Transmission Shift Cable Lever [A]
Hi/Low Shift Cable Lever [B] (KAF620M/N)
Cable Blacket [C]
• Remove:
2WD/4WD Shift Cable Lower End [A] (KAF620M/N)
Differential Shift Cable Lower End [B]
Neutral Switch Lead Terminal [C]
• Remove:
Engine Positioning Plate [A]
Transmission Case Mounting Bolts [B] and Nuts
Transmission Case [C]
• Adjust:
Transmission Oil (see Transmission Oil Change in the
Periodic Maintenance chapter)
Transmission Shift Cable (see Shift Lever Position Ad-
justment)
Differential Shift Cable (see Differential Shift Cable Ad-
justment)
Hi/Low Shift Cable (see Shift Lever Position Adjustment)
2WD/4WD Shift Cable (KAF620M/N) (see 2WD/4WD
Shift Cable Adjustment)
Transmission Case Splitting
• Remove:
Transmission Case (see Transmission Case Removal)
Cable Bracket [A]
Transmission Case Bolts [B]
Left Transmission Case [C]
• Tighten:
Torque - Transmission Case Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
TRANSMISSION 10-15
Transmission and Shift Mechanism
The KAF620P model is not equipped with a Low position.
Transmission and Hi/Low Shift Cables Installation
• Remove one side of the spring [A] from the shift shaft lever
assembly.
• Using the shift shaft lever [A] temporarily set the shift arm
[B] in forward or reverse position as shown.
• Turn the hi/low shift shaft lever [A] clockwise while turning
the drive shafts (wheels) until the lever engages low gear.
• Screw the joint [A] of the shift shaft lever [B] fully into the
hi/low shift cable end [C], and install the cable onto the
bracket [D].
• Hold the shift shaft lever [A] in the low range position
turning fully clockwise, and then push the outer cable [B]
lightly rearward to remove the cable free play.
• Tighten:
Hi/Low Shift Cable Adjuster Nut [C]
Hi/Low Shift Cable Adjuster Nut [D]
• Put the shift lever [A] in the center of right and left at "N"
(NEUTRAL) position, and hold it at the location [B].
○Install suitable plates [C] between the shift lever and lower
and upper side of the gate in order to fix the shift lever.
TRANSMISSION 10-17
Transmission and Shift Mechanism
• Using the shift shaft lever [A] temporarily set the shift arm
[B] in neutral position as shown.
Punch Mark [C]
Projection [D]
• Screw the joint [A] of the shift shaft lever [B] fully into the
transmission shift cable [C] end, and install the cable onto
the bracket [D].
• Hold the shift shaft lever [A] in the neutral position, and
then pull the outer cable [B] lightly forward to remove the
cable free play.
NOTE
○If the cable cannot be adjusted, move the slit opening in
the shift shaft lever one notch to right side of the punch
mark on the shift arm.
• Tighten:
Transmission Shift Cable Adjuster Nut [C]
Transmission Shift Cable Adjuster Nut [D]
• Install
bly.
the spring [A] back onto the shift shaft lever assem-
• Adjust the hi/low shift cable and set the transmission shift
lever [A] in the correct position as follows.
• The gap [B] between the shift lever and panel is approxi-
mate 1.5 mm (0.06 in.).
○When the outer cable moving forward, the shift lever
moves left side.
○When the outer cable moving rearward, the shift lever
moves right side.
•Tighten:
Hi/Low Shift Cable Adjuster Nuts
• Loosen
[B].
the transmission shift cable adjuster nuts [A] and
Transmission Removal
• Remove:
Hi/Low Shift Gears (see Hi/Low Gear and Shift Mecha-
nism Removal)
2WD/4WD Shift Mechanism (KAF620M/N) (see
2WD/4WD Shift Mechanism Removal)
Transmission Case (see Transmission Case Splitting)
Drive Shaft [A]
Washers [B]
Drive Shaft Reverse Sprocket [C]
Drive Chains [D]
• Remove:
Shift Arm Positioning Bolt Assembly [A]
Retaining Pin [B]
• Lift the shift arm [C] and remove the shifter [D].
• Remove:
Drive Shaft (Outer) [A] and Drive Shaft Forward Gear [B]
Shift Block [C]
Shift Arm [D]
• Remove:
Driven Shaft Assembly [A]
10-20 TRANSMISSION
Transmission and Shift Mechanism
• Remove:
Circlips [A]
Driven Shaft Reverse Sprocket [B]
Driven Shaft Forward Gear [C]
Driven Shaft [D]
Special Tool - Outside Circlip Pliers: 57001-144
Transmission Installation
• 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.
• Remove:
Hi/Low Gear Case Bolts [A]
Hi/Low Gear Case [B]
• Remove:
Washer [A]
High Gear [B] and Washer
Shifter [C]
Reduction Gear [D]
TRANSMISSION 10-23
Hi/Low Gears and Shift Mechanism
• Remove:
Circlip [A]
Washer [B]
Low Gear [C]
Collar
Special Tool - Outside Circlip Pliers: 57001-144
• Remove:
Bolt [A]
Holder [B]
• Remove:
Retaining Pin [A]
Shift Shaft and Arm [B]
• Install the shifter [A] so that the large dogs [B] face to the
low gear [C].
10-24 TRANSMISSION
Hi/Low Gears and Shift Mechanism
• Install:
Reduction Gear
Washer [A]
• Install the high gear [B] so that the small gear side [C]
faces shifter side.
• Replace the hi/low gear case gasket [A] with a new one.
• Washer [B]
Install:
Shifter [C]
• Check to see that the hi/low gear case dowel pins [D] are
in place on the transmission case.
• Fit the shift arm pins [A] into the shifter grooves [B] and
install the hi/low gear case.
• Tighten:
Torque - Hi/Low Gear Case Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)
• Install the 2WD/4WD shift cable [A] to the shift shaft lever
[B] and cable bracket [C].
• Remove:
Shift Shaft Lever Mounting Nut [A]
Shift Shaft Lever [B]
Spring [C]
• Remove:
O-ring [A]
Shift Shaft [B]
• Remove:
Shifter [A]
Circlip [B]
Speedometer Gear [C]
Collar
Special Tool - Outside Circlip Pliers: 57001-144
• Install the shifter so that the dogs [A] face to the outside.
• Install the shift shaft lever [C] on the shift shaft so that the
center of the lever hole with the mark [D] as shown in the
figure.
• Tighten the shift shaft lever mounting nut [E].
• Hook the spring end.
• Check that each gear and shifter spins or slides freely on
its shaft without binding after assembly.
2WD/4WD Shift Mechanism Inspection
• Visually inspect the following parts.
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.
• Replace parts worn beyond the service limit.
Shifter Block Outside Diameter
Standard: 13.95 ∼ 14.00 mm (0.549 ∼ 0.551 in.)
Service Limit: 13.8 mm (0.543 in.)
• Visually inspect:
Shift Arm Pin [A]
Dogs on Differential Gear Housing [B]
If they are damaged or worn excessively, replace them.
• Remove:
Differential Gear Assembly [A]
10-32 TRANSMISSION
Differential Gears and Shift Mechanism
• 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
NOTE
○Use the spacers of the same thickness as a set.
○Do not use the spacers of 1.2 mm (0.047 in.) and 1.0
mm (0.039 in.) thickness at the same time.
TRANSMISSION 10-33
Differential Gears and Shift Mechanism
Differential Gear Inspection
• Visually inspect the differential gears [A].
Replace the gears as a set if either gear is damaged.
10-34 TRANSMISSION
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
• Using a press and the bearing driver set, install the new
bearings and/or new oil seals.
Special Tool - Bearing Driver Set: 57001-1129
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Wheel Alignment .................................................................................................................... 11-5
Toe-in Adjustment ............................................................................................................. 11-5
Wheels (Rims) ........................................................................................................................ 11-7
Wheel Removal................................................................................................................. 11-7
Wheel Installation.............................................................................................................. 11-7
Wheel (Rim) Inspection..................................................................................................... 11-7
Wheel (Rim) Replacement................................................................................................ 11-7
Tires ....................................................................................................................................... 11-9
Tire Removal..................................................................................................................... 11-9
Tire Installation.................................................................................................................. 11-9
Tire Inspection .................................................................................................................. 11-10
11
11-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 11-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
Wheel Nuts (KAF620M9 ∼ MB/N9/P9 ∼ PB 137 14.0 101
1
Wheel Nuts (KAF620MC ∼/PC ∼) 110 11.2 81.1
11-4 WHEELS/TIRES
Specifications
Toe-in Adjustment
• Lift the front wheels off the ground.
• Apply
tires.
a heavy coat of chalk near the center of the front
• Loosen the locknuts [A] on each tie-rod and turn the ad-
justing rods [B] the same number of turns and the same
direction on both sides to achieve the specified toe-in.
11-6 WHEELS/TIRES
Wheel Alignment
NOTE
○The toe-in will be near the specified range, if the length
of the tie-rod distance between the dust boot end [A] of
steering gear assembly and the locknut [B] is 43.5 mm
(1.71 in.) [C] on both the left and right tie-rods.
• Tighten:
Torque - Tie-Rod End Locknuts: 44 N·m (4.5 kgf·m, 32 ft·lb)
• Check the toe-in again.
• Test drive the vehicle.
WHEELS/TIRES 11-7
Wheels (Rims)
Wheel Removal
•○Loosen the wheel nuts [A].
Do not remove the wheel nuts.
• Lift the wheel(s) off the ground.
• Wheel Nuts
Remove:
Wheel(s)
Wheel Installation
• Position the wheel so that the valve stem [A] is toward the
outside of the vehicle.
• Tighten:
Torque - Wheel Nuts (KAF620M9 ∼ MB/N9/P9 ∼ PB): 137
N·m (14.0 kgf·m, 101 ft·lb)
Wheel Nuts (KAF620MC ∼/PC ∼): 110 N·m (11.2
kgf·m, 81.1 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.
• 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.
WARNING
Overinflating a tire can cause it to explode, causing
serious injury or death. Be sure to install the valve
core whenever inflating the tire, and do not inflate
the tire to more than maximum pressure.
11-10 WHEELS/TIRES
Tires
• Check to see that the rim lines [A] on both sides of the tire
are parallel with the rim flanges [B].
If the rim lines and the rim flanges are not parallel, deflate
the tire, lubricate the sealing surfaces again, and reinflate
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.
Tire Air Pressure (when Cold)
Front: 69 kPa (0.70 kgf/cm², 10 psi)
Rear: 167 kPa (1.70 kgf/cm², 24 psi)
Tire Inspection
• Refer to the Tire Wear Inspection in the Periodic Mainte-
nance chapter.
FINAL DRIVE 12-1
Final Drive
Table of Contents
Exploded View................................... 12-2 Bevel Gear Case Installation ....... 12-21
Specifications .................................... 12-6 Bevel Gear Case Disassembly .... 12-21
Special Tools ..................................... 12-7 Bevel Gear Case Assembly ......... 12-22
Front Final Gear Case ....................... 12-8 Drive Bevel Gear Removal .......... 12-23
Front Final Gear Case Oil Level Drive Bevel Gear Installation ....... 12-23
Inspection ................................. 12-8 Bevel Gear Adjustment ............... 12-24
Front Final Gear Case Oil Backlash Adjustment ................... 12-24
Change...................................... 12-8 Tooth Contact Adjustment............ 12-26
Front Final Gear Case Removal .. 12-9 Bevel Gear Inspection.................. 12-28
Front Final Gear Case Installation 12-9 Ball Bearing Inspection ................ 12-28
Front Final Gear Case Oil Seal Inspection ....................... 12-28
Disassembly.............................. 12-10 Damper Inspection....................... 12-28
Front Final Gear Case Assembly. 12-10 Propeller Shafts (KAF620M/N) .......... 12-29
Differential Unit and Ring Gear Propeller Shaft Removal .............. 12-29
Disassembly.............................. 12-11 Propeller Shaft Installation ........... 12-30
Differential Unit and Ring Gear Propeller Shaft Bearing Housing
Assembly................................... 12-11 Removal .................................... 12-31
LSD Clutch Torque Inspection ..... 12-12 Propeller Shaft Bearing Housing
LSD Clutch Plate Inspection ........ 12-13 Installation ................................. 12-32
Pinion Gear Unit Disassembly ..... 12-13 Propeller Shaft Inspection............ 12-32
Pinion Gear Unit Assembly .......... 12-13 Drive Shaft and Axles ........................ 12-33
Front Final Bevel Gear Front Axle Removal .................... 12-33
Adjustment ................................ 12-14 Front Axle Installation ................. 12-33
Backlash Adjustment ................... 12-17 Rear Drive Shaft and Axle 12
Tooth Contact Adjustment............ 12-18 Removal .................................... 12-33
Bevel Gear Inspection.................. 12-20 Rear Drive Shaft and Axle
Differential Gear Inspection ......... 12-20 Installation ................................. 12-34
Tapered Roller Bearing Drive Shaft and Axle Inspection... 12-34
Inspection.................................. 12-20 Dust Boot Inspection.................... 12-35
Ball Bearing Inspection ................ 12-20 Front Axle Joint Boot
Oil Seal Inspection ....................... 12-20 Replacement ............................. 12-35
Bevel Gear Case (KAF620M/N) ........ 12-21 Ball Bearing Inspection ................ 12-41
Bevel Gear Case Removal .......... 12-21 Grease Seal Inspection................ 12-42
12-2 FINAL DRIVE
Exploded View
FINAL DRIVE 12-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Differential Case Torx Bolts 32 3.3 24
2 Front Axle Cap Bolts 8.8 0.90 78 in·lb
3 Gear Case Bracket Bolts 44.1 4.5 33
4 Gear Case Mounting Nuts 44.1 4.5 33 R
5 Oil Drain Plug 20 2.0 15
6 Oil Filler Cap 29 3.0 21
7 Pinion Gear Bearing Housing Nuts 25 2.5 18
8 Pinion Gear Slotted Nut 118 12.0 87.0 MO
9 Ring Gear Bolts 49 5.0 36
10 Ring Gear Cover Bolts (M10) 47 4.8 35 S
11 Ring Gear Cover Bolts (M8) 25 2.5 18 S
12. KAF620M9/N9/P9
G: Apply grease.
HO: Apply hypoid gear oil.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
12-4 FINAL DRIVE
Exploded View
FINAL DRIVE 12-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Bearing Holder 118 12.0 87.0 L
2 Bevel Gear Case Bolts 22 2.2 16
3 Bevel Gear Case Holder Nuts 25 2.5 18
4 Drive Gear Nut 118 12.0 87.0 MO
5 Drive Shaft Cap Bolts 20 2.0 15
6 Driven Gear Shaft Nut 108 11.0 79.7 L
7 Housing Locknut 118 12.0 87.0 L
8 Propeller Shaft Bearing Housing Cover Bolts 3.4 0.35 30 in·lb
9 Speed Sensor Bolt 8.8 0.90 78 in·lb
10. KAF620M/N
11. KAF620M9 ∼ MC/N9/P9 ∼ PC
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
TO: Apply transmission oil.
12-6 FINAL DRIVE
Specifications
• Remove:
Filler Cap [A]
NOTICE
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 of the filler opening [A].
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. 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, 21 ft·lb)
• Replace the front final gear case skid plate nuts with new
ones and install the skid plate.
Front Final Gear Case Oil Change
• Refer to Front Final Gear Case Oil Change in the Periodic
Maintenance chapter.
FINAL DRIVE 12-9
Front Final Gear Case
Front Final Gear Case Removal
• Remove:
Front Final Gear Case Oil (drain)
Radiator (see Radiator Removal in the Cooling System
chapter)
Propeller Shafts (see Propeller Shaft Removal)
Front Axles (see Front Axle Removal)
Vent Hose [A]
Front Final Gear Case Mounting Bolts [B], Nuts and
Washer
Collar [C]
• Remove:
Front Final Gear Case Bracket Bolts [A]
Front Final Gear Case Bracket [B]
• Remove:
Front Final Gear Case [A] with Mounting Bolt [B]
• Remove:
Spacers [A] (both sides)
• Remove
bolts [B].
the ring gear cover bolts, starting with the smaller
• Remove:
Ring Gear [A]
Differential Unit [B]
• 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 (0.39 in.) bolts, then tighten the 8
mm (0.31 in.) bolts.
Torque - 10 mm Ring Gear Cover Bolts (M10): 47 N·m (4.8
kgf·m, 35 ft·lb)
8 mm Ring Gear Cover Bolts (M8): 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)
Differential Unit and Ring Gear Disassembly
• Remove the differential unit and ring gear (see Front Final
Gear Case Disassembly).
NOTICE
Do not interchange the right and left side parts in
the differential unit.
• Remove
unit.
the following parts to disassemble the differential
• 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, kg),
and when measured with a torque wrench, it is desig-
nated by torque (N·m, kgf·m, in·lb).
12-16 FINAL DRIVE
Front Final Gear Case
FINAL DRIVE 12-17
Front Final Gear Case
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.
○Change the thickness a little at a time.
•Recheck the bearing preload, and readjust as necessary.
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.
• Case Assembly).
Assemble the front final gear case (see Front Final Gear
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).
○Change the thickness a little at a time.
•Recheck the backlash, and readjust as necessary.
12-18 FINAL DRIVE
Front Final Gear Case
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.
FINAL DRIVE 12-19
Front Final Gear Case
12-20 FINAL DRIVE
Front Final Gear Case
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.
• Remove:
Driven Gear Assembly [A]
Driven Gear Shim(s) [B]
12-22 FINAL DRIVE
Bevel Gear Case (KAF620M/N)
• Remove:
Housing Locknut
Bearing Housing [A]
Special Tools - Pinion Gear Holder: 57001-1281 [C]
Socket Wrench: 57001-1363 [B]
• Remove:
Driven Gear Shaft Nut [A] and Washer
Special Tool - Pinion Gear Holder: 57001-1281 [B]
○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
• Set the hi/low gear case [A] onto the gear holder.
• Drive Gear Nut [B]
Remove:
• Remove:
Drive Gear [A]
Drive Gear Shim(s) [B]
Drive Gear Shaft [C]
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.
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
FINAL DRIVE 12-27
Bevel Gear Case (KAF620M/N)
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.
[A] Drive Bevel Gear
[B] Driven Bevel Gear
[C] Bottom
[D] Top
[E] Heel
[F] Toe
• Remove:
Water Pipe Bracket Bolt [A]
• Remove:
Bracket Bolts [A]
• Remove:
Propeller Shaft Bearing Housing Mounting Bolts [A] and
Nuts
• Move the water pipe [A] and the propeller shaft bearing
housing [B] to the outside [C].
• Remove:
Rear Propeller Shaft [D]
Front Propeller Shaft [E]
12-30 FINAL DRIVE
Propeller Shafts (KAF620M/N)
Propeller Shaft Installation
• Wipe the old grease off the splines of the propeller shafts,
and grease to them.
• Inspect
tion).
the propeller shafts (see Propeller Shaft Inspec-
• Install the rear propeller shaft yoke [D] on the rear driven
gear shaft so that the thin side [E] of the propeller shaft
positions to the rearward.
•Install the rear propeller shaft yoke [F] on the front pro-
peller shaft rear end [G], aligning the yoke angles [H] of
the front and rear propeller shafts.
•Parallel [I] the propeller shaft bearing housing [J] with the
mounting bracket [K].
○Make the 3 mm (0.12 in.) clearance [L] between the yoke
[B] of the front propeller shaft and the front pinion gear nut
[M].
•Replace the propeller shaft bearing housing nuts [Q] with
new ones.
•Install:
Propeller Shaft Bearing Housing Bolts [N]
Washers [O]
Collars [P]
Nuts
FINAL DRIVE 12-31
Propeller Shafts (KAF620M/N)
• Tap [A] the outside of the rear axle [B], and pull it out from
the inside.
12-34 FINAL DRIVE
Drive Shaft and Axles
• Remove:
Drive Shaft Cap Bolts [A]
Drive Shaft [B] and Cap [C]
○Set the differential shift lever into the UN-LOCK position.
• Tap the bearing housing [A] straight [B] with a plastic ham-
mer to separate it from the shaft.
NOTICE
Do not tap on the cage. Be careful not get hurt when
the housing comes out. If the splined portion of
shaft cracked or damaged during disassembling of
outboard joint, do not reuse the shaft.
• Remove:
Circlip [A]
Boot [B]
12-36 FINAL DRIVE
Drive Shaft and Axles
Outboard Joint Boot Installation
•Clean the axle shaft by wiping off the used grease on it.
•Wind the tape on the splines of the axle shaft in order to
protect the joint boot.
•Install:
New Small Band [A]
New Boot [B]
○Apply the special grease slightly on the inside of the new
boot small diameter, and install the boot on the axle shaft.
NOTICE
Only the special grease that is included with the
boot kit can be applied to the boots.
• Install:
New Circlip [C]
• Tap the shaft end [A] straight with a plastic hammer until
it is locked by the circlip.
• Pinch the small boot band [A] with a suitable tool [B] to
install it.
○Slightly open [A] the larger diameter end of the joint boot
to equalize the air pressure inside the boot.
• Pinch
it.
the boot bands [A] with a suitable tool [B] to install
• Remove:
Front Axle (see Front Axle Removal)
• Tap the joint portion of the bands [A] with a suitable tool.
• Slide the
Scrap the removed boot bands.
• joint boot [B] toward the outboard joint.
• Remove:
Circlip [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
FINAL DRIVE 12-39
Drive Shaft and Axles
• Remove:
Inner Race [A]
Cage [B]
Inboard Joint Boot [C]
• Install the inner race [A] so that the flat serration side [B]
faces outboard joint.
• Install:
Circlip [A]
Special Tool - Outside Circlip Pliers: 57001-144
• Slide the cage [B] on the inner race and install the steel
balls [C].
• Apply the special grease [A] to the steel balls and cage.
12-40 FINAL DRIVE
Drive Shaft and Axles
• Install the axle shaft [A] into the bearing cap [B].
• Install the new retaining ring [A] so that the opening [B] is
aligned with one of the projections [C].
• Pinch the small boot band [A] with a suitable tool [B] to
install it.
FINAL DRIVE 12-41
Drive Shaft and Axles
○Slightly open [A] the larger diameter end of the joint boot
to equalize the air pressure inside the boot.
• Pinch
them.
the boot bands [A] with a suitable tool [B] to install
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 Changing ....................................................................................................... 13-8
Brake Line Air Bleeding ................................................................................................... 13-9
Brake Pedal and Master Cylinder .......................................................................................... 13-10
Brake Pedal Free Play Adjustment ................................................................................... 13-10
Master Cylinder Removal.................................................................................................. 13-10
Master Cylinder Installation............................................................................................... 13-10
Master Cylinder Disassembly ........................................................................................... 13-10
Master Cylinder 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
Brake Panel Removal ....................................................................................................... 13-15
Brake Panel Installation .................................................................................................... 13-16
Wheel Cylinder Assembly ................................................................................................. 13-18 13
Wheel Cylinder Inspection ................................................................................................ 13-18
Brake Shoe Lining Wear ................................................................................................... 13-18
Brake Shoe Spring Inspection .......................................................................................... 13-19
Parking Brake Lever and Cables............................................................................................ 13-20
Parking Brake Lever Travel Adjustment .......................................................................... 13-20
Parking Brake Cable Lubrication ...................................................................................... 13-20
Parking Brake Cable Inspection........................................................................................ 13-20
13-2 BRAKES
Exploded View
BRAKES 13-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Bleed Valves 7.8 0.80 69 in·lb
2 Brake Hose Banjo Bolts 25 2.5 18
3 Brake Panel Mounting Bolts 44.1 4.5 33 L
4 Brake Pipe Nipples 17.7 1.8 13 B
5 Front Axle Nuts 196 20.0 145
6 Master Cylinder Push Rod Locknut 17.2 1.8 13
7 Master Cylinder Reservoir Cap 3.5 0.36 31 in·lb
8 Piston Stop Bolt 8.9 0.91 79 in·lb
9 Reservoir Clamp Bolt 6.2 0.63 55 in·lb
10 Wheel Cylinder Mounting Bolts 10.3 1.1 91 in·lb
11. Front Axles (KAF620P)
12. Band for Breather Tube of Early Model for KAF620M9/N9/P9
13. Breather Tube (Early Model for KAF620M9/N9/P9: L = 1 480 mm (58.3 in.), Late Model for
KAF620M9/N9/P9 and Later Model: L = 1 100 mm (43.3 in.))
AG: Apply lithium grease (NLGI Grade No.2).
B: Apply brake fluid.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease.
WL: Apply soap and water solution or rubber lubricant.
13-4 BRAKES
Exploded View
BRAKES 13-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Bleed Valves 7.8 0.80 69 in·lb
2 Brake Panel Mounting Bolts 44.1 4.5 33 L
3 Brake Pipe Nipples 17.7 1.8 13 B
4 Rear Axle Nuts 304 31.0 224
5 Wheel Cylinder Mounting Nuts 7.4 0.75 65 in·lb
AG: Apply lithium grease (NLGI Grade No.2).
B: Apply brake fluid.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
13-6 BRAKES
Specifications
WARNING
Brake fluid that is contaminated by moisture or dirt,
mixed or contains air has a lower boiling point and
can cause the brake to be ineffective or fail, and it
may cause rubber parts to deterioate, resulting in
an accident causing injury or death. Never reuse
old brake fluid. Do not use fluid from a container
that has been left unsealed or that has been open
for a long time. Do not mix two types and brands
of fluid for use in the brake. Don’t leave the reser-
voir cap off for any length of time to avoid moisture
contamination of the fluid. Don’t add or change the
fluid in the rain or when a strong wind is blowing.
If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
NOTICE
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
• 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.
• Remove the wheel for extra clearance (see Wheel Re-
moval in the Wheels/Tires chapter).
• Connect a clear plastic hose 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.
• Remove:
Master Cylinder Mounting Bolts [C]
Master Cylinder [D]
Master Cylinder Installation
• Use a new flat washer on each side of the brake hose
fitting.
• Apply brake fluid:
Brake Pipe Nipple Threads
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Nipple: 17.7 N·m (1.8 kgf·m, 13 ft·lb)
• Bleed the brake line after master cylinder installation.
• Brake Pedal Free Play Adjustment
Adjust:
• Check that the brake line has proper fluid pressure and
no fluid leakage.
Master Cylinder Disassembly
• Refer to the Brake Master Cylinder Cup and Dust Seal
Replacement in the Periodic Maintenance chapter.
Master Cylinder 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
• 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 them.
• Inspect the primary cups and secondary cups.
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 for damage.
If it is damaged, replace it.
• Check that the relief and supply 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 for any damage.
If the spring is damaged, replace it.
13-12 BRAKES
Brake Hoses and Pipes
Brake Hose and Pipe Inspection
• Refer to the Brake Hose and Pipe Inspection in the Peri-
odic Maintenance chapter.
Brake Hose and Pipe Replacement
• Refer to the Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter.
BRAKES 13-13
Brake Drums
Brake Drum Removal
• Remove:
Wheel (see Wheel Removal in the Wheels/Tires chapter)
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: 57001-1325
• Be sure to release the parking brake when removing the
rear brake drum.
• Install:
Collar [A] (Rear Brake only)
Brake Drum
13-14 BRAKES
Brake Drums
• Tighten:
Torque - Front Axle Nuts: 196 N·m (20.0 kgf·m, 145 ft·lb)
Rear Axle Nuts: 304 N·m (31.0 kgf·m, 224 ft·lb)
• Remove:
Brake Shoe Springs [A]
Brake Shoes [B]
○Push the shoe hold-down spring [C] and twist the pin [D]
to remove them.
NOTE
○Hold the brake shoes with a clean cloth to protect the
linings from grease or dirt.
• Remove:
Brake Panel Mounting Bolts [A]
Brake Panel [B]
○Rear brake; pry the ratchet lever [A] with a screwdriver [B]
to reset the shoe clearance adjuster in its original position
[C].
BRAKES 13-17
Brake Panel Assemblies
• Adjust:
Parking Brake Lever Travel Adjustment (see Parking
Brake Lever Travel Adjustment in the Periodic Mainte-
nance chapter)
13-18 BRAKES
Brake Panel Assemblies
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.
NOTICE
Use only brake fluid, isopropyl alcohol, or ethyl al-
cohol, for cleaning brake parts. Do not use any
other fluid for cleaning these parts. Gasoline, mo-
tor oil, or any other petroleum distillate will cause
deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely, and will
eventually deteriorate the rubber used in the brake.
Suspension
Table of Contents
Exploded View........................................................................................................................ 14-2
Struts and Rear Shock Absorbers .......................................................................................... 14-4
Strut (Front Shock Absorber) Removal............................................................................. 14-4
Strut (Front Shock Absorber) Installation.......................................................................... 14-4
Strut Spring Replacement................................................................................................. 14-5
Rear Shock Absorber Removal ........................................................................................ 14-6
Rear Shock Absorber Installation ..................................................................................... 14-6
Shock Absorber Inspection ............................................................................................... 14-7
Front Suspension Arms .......................................................................................................... 14-8
Front Suspension Arm Removal ....................................................................................... 14-8
Front Suspension Arm Installation .................................................................................... 14-8
Front Suspension Arm Inspection..................................................................................... 14-9
Leaf Springs and Dampers..................................................................................................... 14-10
Leaf Spring Removal ........................................................................................................ 14-10
Leaf Spring Installation ..................................................................................................... 14-10
Leaf Spring Inspection ...................................................................................................... 14-11
14
14-2 SUSPENSION
Exploded View
SUSPENSION 14-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Damper Bracket Mounting Nuts 59 6.0 44 R, S
2 Front Suspension Arm Joint Nuts 78 8.0 58
3 Front Suspension Arm Pivot Bolts 98 10.0 72.3
4 Leaf Spring Mounting Nuts (Front) 98 10.0 72.3
5 Leaf Spring Mounting Nuts (Rear) 59 6.0 44
6 Rear Shock Absorber Mounting Nuts 59 6.0 44 R
7 Strut Clamp Nuts 98 10.0 72.3
8 Strut Locknuts 50 5.1 37
9 Strut Mounting Nuts 44 4.5 32 R
10 Tie-Rod End Nuts 34 3.5 25
11. Right Side
G: Apply grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
14-4 SUSPENSION
Struts and Rear Shock Absorbers
Strut (Front Shock Absorber) Removal
• Remove:
Glove Compartment (see Glove Compartment Removal
in the Frame chapter)
Front Wheel (see Wheel Removal in the Wheels/Tires
chapter)
Brake Panel (see Brake Panel Assy Removal in the
Brakes chapter)
Brake Hose Retainer [A]
• Disconnect the brake hose [B] (from Bracket).
• Remove:
Cotter Pin
Strut Clamp Bolt and Nut [C]
• Remove:
Holder [A]
Thrust Plate [B]
Dust Seal
Thrust Washer
Upper Spring Seat [C]
Dust Cover [D]
Spring [E]
• Install:
Dust Cover [A]
Upper Spring Seat [B]
○Fit the spring end to the bulge [C] in the dust cover and
upper spring seat.
• Install:
Holder [A]
Large Washer [B]
Small Washer [C]
Locknut [D]
○Push down the holder, and tighten the locknut.
Torque - Strut Locknuts: 50 N·m (5.1 kgf·m, 37 ft·lb)
• Tighten:
Torque - Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
SUSPENSION 14-7
Struts and Rear Shock Absorbers
Shock Absorber Inspection
• Visually
tion.
inspect the shock absorber for breaks or distor-
• Remove:
Cotter Pin
Front Suspension Arm Joint Nut [A]
Front Suspension Arm Joint (from Steering Knuckle)
○Remove the front suspension arm joint from the steering
knuckle, using a suitable joint remover (see Steering Gear
Assembly Removal in the Steering chapter).
•Remove the front suspension arm [B].
• Remove:
Rear Shock Absorber [B]
Damper Bracket Mounting Nuts [C]
Damper and Bracket [D]
• Remove:
Clamp [A]
Leaf Spring Mounting Bolt and Nuts [B]
Leaf Spring [C]
• Replace
ones.
the damper bracket mounting nuts with new
Steering
Table of Contents
Exploded View................................... 15-2 Service Code Erasing .................. 15-33
Specifications .................................... 15-4 Service Code Erasing
Special Tools ..................................... 15-5 Procedures................................ 15-36
Steering Wheel and Main Shaft EPS Neutral Position Registration 15-38
Assembly ........................................ 15-6 Power Supply Voltage Abnormal
Steering Wheel Position (Service Code 11,12) ................ 15-41
Adjustment ................................ 15-6 EPS Neutral Position
Steering Wheel Free Play Unregistration (Service
Inspection.................................. 15-6 Code 31) ................................... 15-41
Steering Wheel Centering............ 15-6 Current Sensor Inspection
Steering Wheel and Steering (Service Code 32) ..................... 15-41
Shaft Removal (KAF620M9 ∼ FET (Field Effect Transistor)
MC/N9/P9 ∼ PC) ....................... 15-7 Inspection (Service Code 33).... 15-42
Steering Wheel and Steering Internal Relay Inspection (Service
Shaft Installation (KAF620M9 ∼ Code 34) ................................... 15-42
MC/N9/P9 ∼ PC) ....................... 15-9 CPU (Central Processing Unit)
Steering Wheel and Steering Inspection (Service Code 35).... 15-43
Shaft Removal (KAF620MD Direction Distinction Circuit
∼/PD ∼) ...................................... 15-11 Inspection (Service Code 36).... 15-43
Steering Wheel and Steering Boosting Transformer Circuit
Shaft Installation (KAF620MD Inspection (Service Code 37).... 15-43
∼/PD ∼) ...................................... 15-12 EPS Torque Sensor Inspection
Steering Gear Assembly.................... 15-14 (Service Code 51) ..................... 15-44
Steering Gear Assembly EPS Motor Inspection (Service
Removal .................................... 15-14 Code 61) ................................... 15-45
Steering Gear Assembly EPS Warning Indicator Light
Installation ................................. 15-15 (LED) Removal.......................... 15-46
Steering Gear Preload EPS Warning Indicator Light
Adjustment ................................ 15-17 (LED) Inspection ....................... 15-47
Tie-Rod Length Adjustment ......... 15-17 EPS ECU Removal ...................... 15-48 15
Steering Joint Dust Boot EPS ECU Installation ................... 15-49
Inspection.................................. 15-17 EPS ECU Power Supply Voltage
Steering Knuckles.............................. 15-18 Inspection.................................. 15-50
Steering Knuckle Removal........... 15-18 EPS Motor Removal .................... 15-51
Steering Knuckle Installation........ 15-18 EPS Torque Sensor Removal ...... 15-52
Knuckle Bearing Removal............ 15-19 EPS Unit Removal ....................... 15-52
Knuckle Bearing Installation......... 15-19 EPS Unit Installation .................... 15-54
Knuckle Joint Removal ................ 15-20 Speed Sensor Removal/Installa-
Knuckle Joint Installation ............. 15-20 tion ............................................ 15-56
EPS (Electric Power Steering) Speed Sensor Inspection............. 15-56
System (KAF620M/N)..................... 15-21 EPS ECU Relay Removal/Instal-
EPS System Servicing lation.......................................... 15-56
Precautions ............................... 15-26 EPS ECU Relay Inspection.......... 15-57
EPS System Troubleshooting Diodes Removal/Installation ........ 15-57
Outline....................................... 15-27 Diodes Inspection ........................ 15-57
Inquiries to Rider.......................... 15-31 EPS Fuse 40 A Removal ............. 15-58
Self-diagnosis Outline .................. 15-31 EPS Fuse 7.5 A Removal ............ 15-59
Self-diagnosis Procedure............. 15-32 Fuse Installation........................... 15-59
Service Code Reading ................. 15-33 Fuse Inspection............................ 15-59
15-2 STEERING
Exploded View
STEERING 15-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 EPS Unit Mounting Bolts 20 2.0 15
2 Intermediate Shaft Clamp Bolts 20 2.0 15
3 Rack Guide Spring Cap Locknut 39 4.0 29
4 Steering Gear Assembly Bracket Bolts 52 5.3 38 L
5 Steering Wheel Mounting Nut 52 5.3 38 R
6 Strut Clamp Nuts 98 10.0 72.3
7 Tie-Rod End Locknuts 44 4.5 32
8 Tie-Rod End Nuts 34 3.5 25
9 Universal Joint Clamp Bolts 20 2.0 15
10. KAF620P
11. KAF620M9 ∼ MC/N9/P9 ∼ PC
12. KAF620MD ∼
13. KAF620M9 ∼ MC/N9
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
15-4 STEERING
Specifications
○Insert a thin driver [A] into the hole [B], and unlock the
stopper.
○Pry the one side part of the switch with a thin driver for
the stopper [A] is free.
○Remove the wheel cap [B] together with the horn switch.
• Remove:
Steering Wheel Mounting Nut [A] and Spring Washer
Steering Wheel
• Remove:
Screws [A] and Holder
Horn Switch Contact [B]
(KAF620M/N)
• Remove:
Front Cargo Compartment (see Front Cargo Compart-
ment Removal in the Frame chapter)
Universal Joint Clamp Bolt [A]
• Remove:
Steering Shaft Mounting Bolts, Washers and Nuts [A]
Steering Shaft [B]
(KAF620P)
• Remove:
Main Shaft Mounting Bolts, Washers and Nuts [A]
Clamp Bolt [B]
Maine Shaft [C]
• Remove:
Clamp Bolt [A]
Intermediate Shaft [B]
STEERING 15-9
Steering Wheel and Main Shaft Assembly
Steering Wheel and Steering Shaft Installation
(KAF620M9 ∼ MC/N9/P9 ∼ PC)
• Apply grease to the dust cover lips [A].
(KAF620M/N)
• Install the steering shaft [A] to the upper universal joint
[B].
• Install the universal joint clamp bolt [C] while aligning the
notch on the steering shaft with the clamp bolt hole on the
upper universal joint, and tighten it temporary.
• Replace the steering shaft mounting nuts [F] with new
ones.
• Install the steering shaft mounting bolts [D], washers [E]
and nuts.
• Tighten:
Torque - Universal Joint Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
(KAF620P)
• Connect the intermediate shaft [A] to the steering gear
shaft with the steering gear pinion in any position.
• Replace the main shaft mounting nuts with new ones.
• Install:
Maine Shaft [B]
Main Shaft Mounting Bolts [C], Washers and Nuts
• Tighten:
Torque - Intermediate Shaft Clamp Bolts [D]: 20 N·m (2.0
kgf·m, 15 ft·lb)
15-10 STEERING
Steering Wheel and Main Shaft Assembly
• Install:
Horn Switch Contact [A]
Holder [B]
Screws [C]
○Position the horn switch contact on the projection [D].
• Connect the horn switch lead connector [A] and clamp the
bands [B].
• Mount
ily.
the steering wheel on the steering shaft temporar-
○Fit the rear stopper [A] in the recess of the steering wheel
and push the rear part until sound click.
STEERING 15-11
Steering Wheel and Main Shaft Assembly
• Install the wheel cap [A] so that the arrow mark [B] faces
front and the stoppers [C] fit the recesses [D] of the horn
switch.
• Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
• Remove:
Steering Wheel Mounting Nut [A] and Washer [B]
Steering Wheel
(KAF620M)
• Remove:
Front Cargo Compartment (see Front Cargo Compart-
ment Removal in the Frame chapter)
Universal Joint Clamp Bolt [A]
15-12 STEERING
Steering Wheel and Main Shaft Assembly
• Remove:
Steering Shaft Mounting Bolts, Washers and Nuts [A]
Steering Shaft [B]
(KAF620P)
• Remove:
Front Cargo Compartment (see Front Cargo Compart-
ment Removal in the Frame chapter)
Main Shaft Mounting Bolts, Washers and Nuts [A]
Clamp Bolt [B]
Maine Shaft [C]
• Remove:
Clamp Bolt [A]
Intermediate Shaft [B]
(KAF620M)
• Install the steering shaft [A] to the upper universal joint
[B].
• Install the universal joint clamp bolt [C] while aligning the
notch on the steering shaft with the clamp bolt hole on the
upper universal joint, and tighten it temporary.
• Replace the steering shaft mounting nuts [F] with new
ones.
• Install the steering shaft mounting bolts [D], washers [E]
and nuts.
• Tighten:
Torque - Universal Joint Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
STEERING 15-13
Steering Wheel and Main Shaft Assembly
(KAF620P)
• Connect the intermediate shaft [A] to the steering gear
shaft with the steering gear pinion in any position.
• Replace the main shaft mounting nuts with new ones.
• Install:
Maine Shaft [B]
Main Shaft Mounting Bolts [C], Washers and Nuts
• Tighten:
Torque - Intermediate Shaft Clamp Bolts [D]: 20 N·m (2.0
kgf·m, 15 ft·lb)
• Mount
ily.
the steering wheel on the steering shaft temporar-
• Insert the hook portions [A] into the holes [B] of the steer-
ing wheel.
15-14 STEERING
Steering Gear Assembly
Steering Gear Assembly Removal
• Remove:
Front Wheels (see Wheel Removal in the Wheels/Tires
chapter)
Radiator (see Radiator Removal in the Cooling System
chapter)
Cotter Pins (Both Sides)
Tie-Rod End Nuts [A] (Both Sides)
Tie-Rod Ends [B] from Steering Knuckles (Both Sides)
NOTICE
Do not loosen the tie-rod end locknuts [C], or the
toe-in of the front wheels will be changed.
○Remove the tie-rod end [A] from the steering knuckle, us-
ing a suitable joint remover [B].
• Remove:
Left Radiator Side Cover (see Radiator Side Cover Re-
moval in the Frame chapter)
• Disconnect the water hoses [A].
• Remove:
Horn Ground Lead Terminal [B]
• Remove the steering gear assembly bracket bolts [C] and
brackets [D].
• Move the steering gear assembly, and pull off the shaft
[A] from the lower universal joint [B].
○Lower the steering gear assembly, and then pull it for-
ward.
• Remove the rubber boot [C].
• Install the rubber boot [A] on the shaft [B] of the steering
gear assembly temporary.
• Install the shaft of the steering gear assembly to the lower
universal joint [C].
• Install the universal joint clamp bolt [D] while aligning the
notch on the shaft of the steering gear assembly with the
clamp bolt hole on the lower universal joint, and tighten it
temporary.
• Install:
Rubber Dampers [E]
Brackets [F]
• Apply a non-permanent locking agent to the steering gear
assembly bracket bolts [G] and tighten them evenly.
Torque - Steering Gear Assembly Bracket Bolts: 52 N·m
(5.3 kgf·m, 38 ft·lb)
• Tighten
torque.
the universal joint clamp bolt to the specified
• Install the rubber boot [A] so that the mark (F, Arrow) [B]
faces forward.
• Tighten:
Torque - Tie-Rod End Nuts: 34 N·m (3.5 kgf·m, 25 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, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.
STEERING 15-17
Steering Gear Assembly
• Remove:
Brake Hose Retainer [D]
Cotter Pin
Strut Clamp Bolt and Nut [E]
• Remove:
Cotter Pin
Front Suspension Arm Joint Nut [A]
Front Suspension Arm Joint from Steering Knuckle
○Remove the front suspension arm joint from the steering
knuckle, using a suitable joint remover (see Steering Gear
Assembly Removal).
•Remove the steering knuckle [B].
○Second, move the remover [A] so that its center align with
the center of the knuckle joint.
○Press the knuckle joint, and remove it.
1. Unused
2. Unused
3. Unused
4. Ground for EPS ECU: BK/Y
5. Power Supply (from Battery): W
6. EPS Motor 1 : BK
7. EPS Motor 2 : R
8. External Communication Line: G
9. EPS Warning Indicator Light (LED): BK/W
10. Unused
11. Unused
12. Speed Sensor Signal: P
13. Unused
14. Unused
15. EPS Torque Sensor Signal 1: Y/BK
16. Power Supply (from Ignition Switch): BL/R
17. Unused
18. Unused
19. Unused
20. EPS Self-diagnosis System Terminal: BL
21. Unused
22. Ground for EPS Torque Sensor: BK/BL
23. EPS Torque Sensor Signal 2: Y/R
15-26 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
EPS System Servicing Precautions
There are number of important precautions that should be
followed servicing the EPS system.
Self-diagnosis Outline
The EPS self-diagnosis system has two modes and can
be switched to another mode by connecting terminals of the
EPS self-diagnosis system connector [A].
User Mode
The EPS ECU notifies the rider of troubles in EPS system
by lighting the EPS warning indicator light (LED) when EPS
system parts are faulty, and initiates fail-safe function. In
this case, EPS ECU stops the EPS motor operation.
Dealer Mode
The EPS warning indicator light (LED) emits service code
(s) to show the problem (s) by blinking.
15-32 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
Self-diagnosis Procedure
○When problem occurs with the EPS system, the EPS
warning indicator light (LED) [A] lights up.
NOTE
○Use a fully charged battery when conducting
self-diagnosis. Otherwise, the EPS warning indi-
cator light (LED) blinks very slowly or does not blink.
○Keep the EPS self-diagnosis system connector termi-
nals connected during self-diagnosis, with an auxiliary
lead.
NOTE:
(1):This code appears in the following condition.
○When the EPS ECU was replaced and the EPS neutral position is not registered in the
new EPS ECU.
In this case, the EPS warning indicator light (LED) blinks immediately after engine starts. But,
the service code 31 is not memorized in the EPS ECU. Therefore, the service code 31 will
disappear when the EPS neutral position was registered in the new EPS ECU.
STEERING 15-35
EPS (Electric Power Steering) System (KAF620M/N)
Self-diagnosis Flow Chart
15-36 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
Service Code Erasing Procedures
NOTE
○Keep the self-diagnosis system connector terminals
connected during service code erase mode with an
auxiliary lead.
○The EPS motor does not operate during service code
erase mode.
• Start the service code erase mode with the following pro-
cedure.
○First, turn the ignition switch OFF.
○Second, connect an auxiliary lead to the terminals of the
EPS self-diagnosis system connector by the same pro-
cedure as self-diagnosis mode (see Self-diagnosis Pro-
cedure).
○Third, lift the front wheel off the ground.
○Fourth, turn the steering wheel fully to the left and keep it.
○Fifth, start the engine while turning the steering wheel fully
to the left.
○The EPS warning indicator light (LED) ights up for 4 sec-
onds and goes off.
If the service code is indicated, turn the ignition switch
OFF and repeat from fourth procedure again.
○Sixth, free the hands from the steering wheel after indica-
tor light goes off.
○After 4 seconds, the EPS warning indicator light (LED)
lights up.
○Seventh, turn the steering wheel fully to the left and keep
it, after indicator light lights up.
○After 4 seconds, the EPS warning indicator light (LED)
goes off.
○Eighth, free the hands from the steering wheel after indi-
cator light goes off.
○After 4 seconds, the EPS warning indicator light (LED)
blinks two times. This blink shows that the service code
was erased.
If the EPS warning indicator light (LED) does not blink or
lights up, turn the ignition switch OFF and repeat from
fourth procedure again.
○Lastly, turn the ignition switch OFF within 5 seconds after
indicator light blinks two times, end the service code erase
mode.
If the ignition switch is not turned OFF within 5 seconds,
the EPS ECU starts the EPS neutral position registration.
NOTE
○The EPS neutral position registration is same procedure
as until eighth procedure.
○After finishing the service code erase mode, enter the
self-diagnosis mode again to confirm that the service
codes have been erased. If all codes have been
erased, the EPS warning indicator light (LED) remains
lit and service code is not indicated.
STEERING 15-37
EPS (Electric Power Steering) System (KAF620M/N)
Service Code Erasing Flow Chart
15-38 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
EPS Neutral Position Registration
NOTE
○Keep the self-diagnosis system connector terminals
connected during the EPS neutral position registration
with an auxiliary lead.
○Be sure to lift the front wheel off the ground. The EPS
neutral position can not be registered correctly with the
front wheel on the ground.
○The EPS motor does not operate during EPS neutral
position registration.
• Register
cedure.
the EPS neutral position with the following pro-
• EPS
Set a digital meter to the × 1Ω range and connect it to the
torque sensor connector [A].
• Measure the EPS torque sensor resistance.
EPS Torque Sensor Resistance Inspection
Connections:
(I) Y/R Lead [B] ←→ BK/BL Lead [C]
(II) Y/BK Lead [D] ←→ BK/BL Lead [C]
Standard:
Both Connections: Any Reading Resistance
(reference 10 ∼ 40 Ω at 20°C
(68°F))
If the reading is infinity (∞) Ω, replace the EPS unit (see
EPS Unit Removal/Installation).
STEERING 15-45
EPS (Electric Power Steering) System (KAF620M/N)
If the reading is in specification, disconnect the EPS ECU
connectors and check the wiring for continuity between
main harness connectors.
Wiring Continuity Inspection
EPS ECU Connector [A] ←→
EPS Torque Sensor Connector [B]
Y/BK Lead [C]
Y/R Lead [D]
BK/BL Lead [E]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
If the power supply voltage is good, erase the service
code with the service code erase mode and enter the self
-diagnosis mode again.
If the service code 51 appears again, replace the EPS
ECU (see EPS ECU Removal/Installation).
If the service code 51 disappears, it is a temporary failure.
EPS Motor Inspection (Service Code 61)
• Remove the front cargo compartment (see Front Cargo
Compartment in the Frame chapter).
• Turn the ignition switch OFF.
• Disconnect the EPS motor connector [A].
[B] KAF620M9 ∼ MC/N9
[C] KAF620MD ∼
15-46 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
• EPS
Set a digital meter to the × 1Ω range and connect it to the
motor connector [A].
[B] KAF620M9 ∼ MC/N9
[C] KAF620MD ∼
• Measure the EPS motor resistance.
EPS Motor Resistance Inspection
Connections: R Lead [D] ←→ BK Lead [E]
Standard Any Reading Resistance (reference
(KAF620M9 ∼ 0.15 ∼ 0.19 Ω at 20°C (68°F))
MC/N9):
Standard Any Reading Resistance (reference
(KAF620MD ∼): 0.13 Ω at 20°C (68°F))
If the reading is infinity (∞) Ω, replace the EPS unit (see
EPS Unit Removal/Installation).
If the EPS warning indicator light (LED) [A] does not light
up, replace it (see EPS Warning Indicator Light (LED) Re-
moval).
If the EPS warning indicator light (LED) lights up, check
the following items.
Oil Pressure Switch
Oil Pressure Warning Indicator Light
If the above items are normal, check the wiring for conti-
nuity (Refer to the next wiring diagram).
15-48 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
EPS Warning Indicator Light (LED) Circuit
1. EPS ECU
2. EPS Warning Indicator Light (LED)
3. EPS Fuse 7.5 A
4. Oil Pressure Warning Indicator Light
5. Ignition Switch
6. Battery 12 V
7. Main Fuse 30 A
8. Fuse Box 1
9. Oil Pressure Switch
EPS ECU Removal
NOTICE
Never drop the EPS ECU, especially on a hard sur-
face. Such a shock to the EPS ECU can damage it.
• Remove the band [A] and open the ECU cover [B].
• Remove:
Right Glove Compartment (see Glove Compartment Re-
moval in the Frame chapter)
Screws [A]
EPS ECU [B] (with Cover)
• Remove:
Radiator (see Radiator Removal in the Cooling System
chapter)
Left Radiator Side Cover (see Radiator Side Cover Re-
moval in the Frame chapter)
• Disconnect:
Water Hoses [A]
• Remove the steering gear assembly bracket bolts [B] and
brackets [C].
• Move the steering gear assembly, and pull off the shaft
[A] from the lower universal joint [B].
○Lower the steering gear assembly, and then pull it for-
ward.
• Remove:
Rubber Boot [C]
Universal Joint Clamp Bolt [D]
Lower Universal Joint
• Remove:
Steering Shaft (see Steering Wheel and Steering Shaft
Removal)
Universal Joint Clamp Bolt [A]
Upper Universal Joint [B]
• Disconnect:
EPS Motor Connector [C]
Torque Sensor Connector [D]
[E] KAF620M9 ∼ MC/N9
[F] KAF620MD ∼
• Remove:
Cotter Pin [A]
Pin [B]
Push Rod [C]
Spring [D]
NOTICE
The EPS unit [A] has been adjusted and set with
precision at the factory. Do not try to disassemble
and repair the EPS unit.
[B] KAF620M9 ∼ MC/N9
[C] KAF620MD ∼
• Install the EPS unit so that the EPS torque sensor [A]
faces upside.
• Install the EPS unit mounting bolts [B] and tighten them
temporary.
• Install
unit.
the lower universal joint [C] to the shaft of the EPS
• Install the universal joint clamp bolt [D] while aligning the
notch on the shaft of the EPS unit with the clamp bolt hole
on the lower universal joint, and tighten it temporary.
[E] KAF620M9 ∼ MC/N9
[F] KAF620MD
STEERING 15-55
EPS (Electric Power Steering) System (KAF620M/N)
• Install the rubber boot [A] on the shaft [B] of the steering
gear assembly temporary.
• Install the shaft of the steering gear assembly to the lower
universal joint [C].
• Install the universal joint clamp bolt [D] while aligning the
notch on the shaft of the steering gear assembly with the
clamp bolt hole on the lower universal joint, and tighten it
temporary.
• Install:
Rubber dampers [E]
Brackets [F]
• Apply non-permanent locking agent to the steering gear
assembly bracket bolts [G] and tighten them evenly.
Torque - Steering Gear Assembly Bracket Bolts: 52 N·m
(5.3 kgf·m, 38 ft·lb)
• Tighten
torque.
the EPS unit mounting bolts to the specified
• Install the rubber boot [A] so that the mark (F, Arrow) [B]
faces forward.
• Install the upper universal joint [A] to the shaft of the EPS
unit [B].
• Install the universal joint clamp bolt (lower) [C] while align-
ing the notch on the shaft of the EPS unit with the clamp
bolt hole on the upper universal joint, and tighten it tem-
porary.
• Install the steering shaft [D] to the upper universal joint.
• Install the universal joint clamp bolt (upper) [E] while align-
ing the notch on the steering shaft with the clamp bolt hole
on the upper universal joint, and tighten it temporary.
• Install the steering shaft mounting bolts [F], washers [G]
and nuts [H].
• Tighten all the universal joint clamp bolts to the specified
torque.
Torque - Universal Joint Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
• Install the washer [I]. (KAF620MD ∼)
[J] KAF620M9 ∼ MC/N9
15-56 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
• Mount
ily.
the steering wheel on the steering shaft temporar-
Diodes Removal/Installation
• Tilt up the front seat and remove the diodes [A].
• Installation is the reverse of removal.
Diodes Inspection
• Remove the diodes (see Diodes Removal/installation).
• Set a digital meter to the × 10 Ω or × 100 Ω range and
connect it to the diode terminals to check the resistance
in both directions.
The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the diode unit must be replaced.
NOTE
○The actual meter reading varies with the meter used
and the individual diode, but, generally speaking, the
lower reading should be from the zero to one half the
scale.
15-58 STEERING
EPS (Electric Power Steering) System (KAF620M/N)
EPS Fuse 40 A Removal
NOTICE
Before removing the 40 A fuse [A], be sure to dis-
connect the battery cables to avoid electrical shock.
NOTE
○The EPS fuse 40 A is installing with bolts to the EPS
fuse box 1 [B].
• Pull the EPS fuse 7.5 A [A] straight out of the EPS fuse
box 2 [B].
Fuse Installation
If a fuse fails during operation, inspect the EPS system to
determine the cause, and then replace it with a new fuse
of proper amperage.
○For EPS fuse 40 A, after installing the lead terminals,
tighten the terminal bolts securely.
Fuse Inspection
• Remove the fuse (see EPS Fuse 7.5 A Removal/EPS
Fuse 40 A Removal).
• Refer to the Fuse Inspection in the Electrical System
chapter.
○For EPS fuse 40 A, there is window for inspection in the
upper surface.
FRAME 16-1
Frame
Table of Contents
Exploded View........................................................................................................................ 16-2
Seat and Seat Belts................................................................................................................ 16-10
Seat Removal ................................................................................................................... 16-10
Seat Installation ................................................................................................................ 16-10
Seat Belt Removal ............................................................................................................ 16-10
Seat Belt Installation ......................................................................................................... 16-11
Control Panel.......................................................................................................................... 16-12
Control Panel Removal ..................................................................................................... 16-12
Control Panel Installation .................................................................................................. 16-13
Glove Compartment Removal........................................................................................... 16-13
Front Cargo Compartment...................................................................................................... 16-14
Front Cargo Hood Removal .............................................................................................. 16-14
Front Cargo Hood Installation ........................................................................................... 16-14
Front Cargo Hood Cable Adjustment................................................................................ 16-15
Front Cargo Compartment Removal................................................................................. 16-15
Front Cargo Compartment Installation.............................................................................. 16-15
Cargo Bed .............................................................................................................................. 16-16
Cargo Bed Removal.......................................................................................................... 16-16
Cargo Bed Installation....................................................................................................... 16-16
Front and Rear Bars ............................................................................................................... 16-18
Front Bar Removal............................................................................................................ 16-18
Front Bar Installation......................................................................................................... 16-18
Rear Bar Removal ............................................................................................................ 16-18
Rear Bar Installation ......................................................................................................... 16-19
Cargo Bed Latch Position Inspection................................................................................ 16-19
Cargo Bed Latch Position Adjustment .............................................................................. 16-19
Guard...................................................................................................................................... 16-20
Front Guard Removal ....................................................................................................... 16-20
Fenders .................................................................................................................................. 16-21
Front Fender Removal ...................................................................................................... 16-21
Front Fender Installation ................................................................................................... 16-21
Rear Fender Assembly Removal ...................................................................................... 16-21
Covers .................................................................................................................................... 16-23 16
Front Cover Removal........................................................................................................ 16-23
Front Cover Installation..................................................................................................... 16-23
Front Fender Inner Cover Removal .................................................................................. 16-23
Radiator Side Cover Removal .......................................................................................... 16-24
Front Side Cover Removal................................................................................................ 16-24
Front Side Cover Installation............................................................................................. 16-24
Rear Side Cover Removal ................................................................................................ 16-25
Rear Side Cover Installation ............................................................................................ 16-25
Middle Cover Removal ..................................................................................................... 16-25
Middle Cover Installation................................................................................................... 16-25
Flap Cover Removal ......................................................................................................... 16-26
Flap and Flap Stay Removal............................................................................................. 16-26
Floor Center Panel Removal............................................................................................. 16-26
Floor Center Panel Installation.......................................................................................... 16-27
Rear End Subframe................................................................................................................ 16-28
Rear End Subframe Removal ........................................................................................... 16-28
Rear End Subframe Installation ....................................................................................... 16-28
16-2 FRAME
Exploded View
FRAME 16-3
Exploded View
1. Reflector (CA Model)
2. KAF620M9 ∼ MC/N9/P9 ∼ PC
G: Apply grease.
R: Replacement Parts
16-4 FRAME
Exploded View
FRAME 16-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Battery Holder Nuts 2.0 0.20 18 in·lb
2 Front Bar Mounting Bolts (Lower) 98 10.0 72.3
3 Front Bar Mounting Bolts (Upper) 44 4.5 32
4 Rear Bar Mounting Bolts 44 4.5 32
5 Rear Bar Mounting Nuts 44 4.5 32
6 Seat Belt Buckle Mounting Bolts 34.3 3.5 25
7 Seat Belt Mounting Bolts 34.3 3.5 25
8. KAF620M9/N9/P9, MA/PA
9. CA Model
G: Apply grease.
R: Replacement Parts
16-6 FRAME
Exploded View
FRAME 16-7
Exploded View
This page intentionally left blank.
16-8 FRAME
Exploded View
FRAME 16-9
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Rear End Subframe Mounting Nuts 44.1 4.5 33 R
2 Tail Gate Fixing Lever Screws 4.4 0.45 39 in·lb L
AD: Apply adhesive.
AG: Apply lithium grease (NLGI Grade No.2).
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
16-10 FRAME
Seat and Seat Belts
Seat Removal
• Tilt up the seat [A].
• Remove:
Seat Bracket Nuts [B]
Seat Brackets [C]
Seat
• Remove:
Seat Back Mounting Nuts [A]
Seat Back [B]
Seat Installation
•○Installation is the reverse of removal, note the following.
Replace the seat bracket nuts and seat back mounting
nuts with new ones.
○Apply grease to the inner surface of the seat bracket [A].
○Be careful not to overtighten the seat bracket nuts. After
tightening the nuts, the seat must be moved up and down
smoothly.
• Remove:
Side Mounting Bolts [A] (Left and Right)
Front Cargo Compartment [B]
• Remove:
Air Duct [A]
Rear Bar Mounting Bolts [B] and Nuts
• Remove:
Air Duct [A]
Rear Bar Mounting Bolts [B] and Nuts
Rear Bar [C]
FRAME 16-19
Front and Rear Bars
Rear Bar Installation
•○Be sure the rubber plates [A] are in position.
Plug one hole [B] and plug only half about another hole
[C], using the rubber plate.
• Tighten:
Torque - Rear Bar Mounting Bolts: 44 N·m (4.5 kgf·m, 32
ft·lb)
Rear Bar Mounting Nuts: 44 N·m (4.5 kgf·m, 32
ft·lb)
• Install the removed parts (see appropriate chapter).
Cargo Bed Latch Position Inspection
• Cargo bed latch [A] must rest securely on the cargo bed
hooks [B] without rattling.
If there is rattling or not snug enough, adjust the latch
positions.
• Insert
fender.
the hook portion [A] into the slot [B] of the front
• Install
size.
the front fender, note the following parts [A] [B] [C]
• Remove:
Screws [A]
Bolt [B], Collar and Nut
Rear Fender Stay [C]
• Remove:
Bolts [A], Collars and Nuts
Rear Fender Inner Cover [B]
FRAME 16-23
Covers
Front Cover Removal
• Tilt up the front cargo hood.
• Remove:
Front Fenders (see Front Fender Removal)
Front Guard (see Front Guard Removal)
Screws [A] and Collars (Left and Right)
Bolts [B] and Washers (Left and Right)
• Remove:
Tapping Screws [A] and Collars
Quick Rivets [B]
Front Fender Inner Cover [C] (Front)
• Remove:
Middle Cover (see Middle Cover Removal)
Tapping Screws [A] and Collars
Screws [B]
Nut [C] and Collar
Quick Rivets [D]
Front Fender Inner Cover [E] (Rear)
• Install:
Screws [A] [L = 16 mm (0.63 in.)] and Collars [L = 4 mm
(0.16 in.)]
Screw [B] [L = 16 mm (0.63 in.)] and Collar [L = 6 mm
(0.24 in.)]
Quick Rivets [C]
• Remove:
Flap Stay Mounting Bolts [A]
Flap Stay [B]
• Remove:
Bolts [A]
Throttle Pedal [B]
FRAME 16-27
Covers
• Remove:
Tapping Screws [A]
Floor Center Panel [B]
• Tighten:
Torque - Rear End Subframe Mounting Nuts: 44.1 N·m (4.5
kgf·m, 33 ft·lb)
ELECTRICAL SYSTEM 17-1
Electrical System
Table of Contents
Exploded View................................... 17-2 Resistor Inspection ...................... 17-52
Specifications .................................... 17-8 Ignition System Inspection ........... 17-53
Special Tools ..................................... 17-9 Electric Starter System ...................... 17-55
Wiring Diagram (KAF620M9/N9, Starter Motor Removal................. 17-55
MA) ................................................. 17-10 Starter Motor Installation.............. 17-55
Wiring Diagram (KAF620MB ∼ MC) .. 17-12 Starter Motor Disassembly........... 17-55
Wiring Diagram (KAF620MD)............ 17-14 Starter Motor Assembly ............... 17-57
Wiring Diagram (KAF620ME) ............ 17-16 Carbon Brush Inspection ............. 17-58
Wiring Diagram (KAF620P9/PA) ....... 17-18 Yoke Inspection............................ 17-58
Wiring Diagram (KAF620PB ∼ PC).... 17-20 Brush Plate Inspection ................. 17-58
Wiring Diagram (KAF620PD) ............ 17-22 Commutator Cleaning/Inspection. 17-58
Wiring Diagram (KAF620PE)............. 17-24 Armature Inspection..................... 17-59
Parts Location.................................... 17-26 Pinion Gear Inspection................. 17-59
Precautions........................................ 17-29 Starter Switch Inspection ............. 17-59
Electrical Wiring................................. 17-30 Starter Relay Removal................. 17-60
Wiring Inspection ......................... 17-30 Starter Relay Inspection............... 17-60
Battery ............................................... 17-31 Starter Relay Installation.............. 17-60
Battery Removal .......................... 17-31 Starter Circuit Relay Inspection ... 17-60
Battery Installation ....................... 17-32 Radiator Fan System......................... 17-62
Battery Activation (CA Model)...... 17-33 Radiator Fan Motor Inspection..... 17-62
Precautions .................................. 17-35 Radiator Fan Breaker Inspection . 17-62
Interchange .................................. 17-36 Lighting System ................................. 17-64
Charging Condition Inspection..... 17-36 Headlight Beam Adjustment ........ 17-64
Refreshing Charge ...................... 17-37 Headlight Bulb Replacement ....... 17-64
Charging System ............................... 17-39 Headlight Removal....................... 17-64
Alternator Rotor and Stator Headlight Installation.................... 17-65
Removal .................................... 17-39 Tail/Brake Light Replacement ...... 17-65
Alternator Rotor and Stator Light Switch Bulb Replacement ... 17-65
Installation ................................. 17-40 Indicator Light Bulb Replacement 17-67
Charging Voltage Inspection ........ 17-41 Meter (KAF620MD ∼/PD ∼) ............... 17-69
Alternator Inspection .................... 17-42 Fuel Gauge/Hour Meter Removal 17-69
Regulator/Rectifier Inspection...... 17-43 Fuel Gauge/Hour Meter
Ignition System .................................. 17-48 Installation ................................. 17-69
Spark Plug Removal/Installation .. 17-48 Fuel Gauge (LED) Inspection ...... 17-69
Spark Plug Gap Inspection .......... 17-48 Switches ............................................ 17-70
17
Spark Plug Cleaning/Inspection... 17-48 Brake Light Switch Adjustment .... 17-70
Ignition Coil Removal ................... 17-48 Water Temperature Sensor
Ignition Coil Installation ................ 17-49 Inspection.................................. 17-70
Ignition Coil Inspection................. 17-49 Switch Inspection ......................... 17-70
Ignition Coil Primary Peak Voltage Fuses................................................. 17-71
Inspection.................................. 17-50 Fuse Removal.............................. 17-71
Crankshaft Sensor Removal ........ 17-50 Fuse Installation........................... 17-71
Crankshaft Sensor Inspection...... 17-51 Fuse Inspection............................ 17-71
Crankshaft Sensor Peak Voltage
Inspection.................................. 17-51
17-2 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 17-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Alternator Rotor Nut 118 12.0 87.0
2 Battery Holder Nuts 2.0 0.20 18 in·lb
3 Neutral Switch 15 1.5 11
4 Oil Pressure Switch 9.8 1.0 87 in·lb SS
5 Spark Plugs 17 1.7 13
6 Speed Sensor Bolt 8.8 0.90 78 in·lb
7 Starter Motor Cable Terminal Nut 8.8 0.90 78 in·lb
8 Starter Motor Mounting Bolts 21.6 2.2 16
9. CA Model
10. KAF620P
11. Tube:
KAF620M9/N9/P9: Engine No. 485833 ∼ and late model
12. Tube:
KAF620M9/N9/P9: Engine No. ∼ 485832
13. KAF620ME
14. KAF620M9 ∼ MD/N9/P9 ∼ PD
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.
TO: Apply transmission oil.
17-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 17-5
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 ECU Mounting Bolts 8.8 0.90 78 in·lb
2 Regulator/Rectifier Mounting Bolts 8.8 0.90 78 in·lb
3 Water Temperature Sensor 22 2.2 16
4. KAF620MB ∼ MC
5. KAF620MC ∼/PC ∼
6. KAF620M9 ∼ MC/N9/P9 ∼ PC
7. KAF620M9 ∼ MD/N9/P9 ∼ PD
R: Replacement Parts
17-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 17-7
Exploded View
1. KAF620M9 ∼ MC/N9/P9 ∼ PC
2. KAF620MD ∼/PD ∼
17-8 ELECTRICAL SYSTEM
Specifications
Grip:
57001-1591
17-10 ELECTRICAL SYSTEM
Wiring Diagram (KAF620M9/N9, MA)
ELECTRICAL SYSTEM 17-11
Wiring Diagram (KAF620M9/N9, MA)
17-12 ELECTRICAL SYSTEM
Wiring Diagram (KAF620MB ∼ MC)
ELECTRICAL SYSTEM 17-13
Wiring Diagram (KAF620MB ∼ MC)
17-14 ELECTRICAL SYSTEM
Wiring Diagram (KAF620MD)
ELECTRICAL SYSTEM 17-15
Wiring Diagram (KAF620MD)
17-16 ELECTRICAL SYSTEM
Wiring Diagram (KAF620ME)
ELECTRICAL SYSTEM 17-17
Wiring Diagram (KAF620ME)
17-18 ELECTRICAL SYSTEM
Wiring Diagram (KAF620P9/PA)
ELECTRICAL SYSTEM 17-19
Wiring Diagram (KAF620P9/PA)
17-20 ELECTRICAL SYSTEM
Wiring Diagram (KAF620PB ∼ PC)
ELECTRICAL SYSTEM 17-21
Wiring Diagram (KAF620PB ∼ PC)
17-22 ELECTRICAL SYSTEM
Wiring Diagram (KAF620PD)
ELECTRICAL SYSTEM 17-23
Wiring Diagram (KAF620PD)
17-24 ELECTRICAL SYSTEM
Wiring Diagram (KAF620PE)
ELECTRICAL SYSTEM 17-25
Wiring Diagram (KAF620PE)
17-26 ELECTRICAL SYSTEM
Parts Location
Light Switch [A]
Oil Pressure Warning Indicator Light [B]
Water Temperature Warning Indicator Light [C]
Horn Button [D]
Parking Brake Indicator Light [E]
DFI Warning Indicator Light [F]
EPS Warning Indicator Light (LED) [G] (KAF620M/N)
[H] KAF620M9 ∼ MC/N9/P9 ∼ PC
[I] KAF620MD ∼/PD ∼
Horn [A]
Radiator Fan [B]
Brake Light Switch [C]
ELECTRICAL SYSTEM 17-27
Parts Location
Fuel Pump [A]
Radiator Fan Breaker [B]
Battery [A]
Regulator/Rectifire [B]
Alternator [A]
Crankshaft Sensor [B]
Oil Pressure Switch [C]
Battery Removal
• Turn off the ignition switch.
• Remove:
Quick Rivets [A]
Screws [B]
Battery Cover [C]
• Remove:
Battery Holder Nuts [B] and Holder Rods
Battery Holder [C]
NOTICE
Each battery comes with its own specific elec-
trolyte container; using the wrong container may
overfill the battery with incorrect electrolyte, which
can shorten battery life and deteriorate battery per-
formance. Be sure to use the electrolyte container
with the same model name as the battery since the
electrolyte volume and specific gravity vary with
the battery type.
NOTICE
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
DANGER
Sulfuric acid in battery electrolyte can cause severe
burns. To prevent burns, wear protective clothing
and safety glasses when handling electrolyte. If
the electrolyte comes in contact with your skin or
eyes, wash the area with liberal amounts of water
and seek medical attention for more severe burns.
• After filling, let the battery sit for 20 ∼ 60 minutes with the
electrolyte container kept in place, which is required for
the electrolyte to fully permeate into the plates.
• Make sure that the container cells have emptied com-
pletely, and remove the container from the battery.
• Place the strip of caps [A] loosely over the filler ports,
press down firmly with both hands to seat the strip of caps
into the battery (don’t pound or hammer). When properly
installed, the strip of caps will be level with the top of the
battery.
NOTICE
Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.
NOTE
○Charging the battery immediately after filling can
shorten service life.
ELECTRICAL SYSTEM 17-35
Battery
Initial Charge
• Newly activated sealed batteries require an initial charge.
Standard Charge: 1.8 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO2
Yuasa MB-2040/2060
Christie C10122S
If the above chargers are not available, use equivalent
one.
• Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter. (Voltage immediately after
charging becomes temporarily high. For accurate mea-
suring, let the battery sit for given time.)
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.8 V, repeat
charging cycle.
○To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying
off the sealing plug to add water is very dangerous. Never do that.
2) Refreshing charge
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above.
Never remove the seal caps during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the safety valve
operates to keep the battery safe.
3) When you do not use the vehicle for months
Give a refresh charge before you store the vehicle and store it with the negative lead removed.
Give a refresh charge once a month during storage.
4) Battery life
If the battery will not start the engine even after several refresh charges, the battery has ex-
ceeded its useful life. Replace it. (Provided, however, the vehicle’s starting system has no prob-
lem.)
17-36 ELECTRICAL SYSTEM
Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri-
ous injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medial at-
tention for more severe burns.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electri-
cal system. Therefore, replace a sealed battery only on a vehicle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a vehicle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
(US Model)
Terminal Voltage: 11.8 ∼ less than 12.6 V
Standard Charge (see following chart)
2 A × 4 ∼ 12 h
6A×2∼6h
(CA Model)
Terminal Voltage: 11.5 ∼ less than 12.8 V
Standard Charge
1.8 A × 5 ∼ 10 h (see following chart)
Quick Charge
9.0 A × 1.0 h
NOTICE
If possible, do not quick charge. If the quick charge
is done due to unavoidable circumstances, do the
standard charge later on.
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery will
accept current [D], decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
17-38 ELECTRICAL SYSTEM
Battery
(CA Model)
Criteria Judgement
12.8 V or higher Good
12.0 ∼ 12.7 V or lower Charge insufficient → Recharge
12.0 V or lower Unserviceable → Replace
ELECTRICAL SYSTEM 17-39
Charging System
Alternator Rotor and Stator Removal
• Remove:
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Propeller Shafts (see Propeller Shaft Removal in the Fi-
nal Drive chapter)
Air Duct of Air Cleaner
Alternator Cover Nuts [A]
Alternator Cover Bolts [B]
Alternator Cover [C]
• Remove:
Crankshaft Sensor (see Crankshaft Sensor Removal)
• Hold the alternator rotor [A] with the holder [B], and re-
move the alternator nut [C] and washer.
Special Tool - Rotor Holder: 57001-1727
• Using the rotor puller [A] and grip [B], remove the alterna-
tor rotor [C] from the crankshaft.
Special Tools - Grip: 57001-1591
Rotor Puller: 57001-1623
NOTE
○If a puller is not available, screw the alternator rotor nut
flush with the shaft end to prevent damaged shaft end
threads and tap sharply and squarely on the nut to break
the rotor loose.
NOTICE
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
17-40 ELECTRICAL SYSTEM
Charging System
• Remove:
Bolts [A]
Breather Cover [B]
Bands [C]
Grommet [D]
• Remove:
Alternator Stator Mounting Screws [A]
Alternator Stator [B]
• Clean off any oil or dirt on the tapered portion [A] of the
alternator rotor and crankshaft, and dry them with a clean
cloth.
• Fit the alternator rotor onto the crankshaft taper so that
the woodruff key [B] fits in the key way [C] in the hub of
the alternator rotor.
• Install:
Washer
• Hold the alternator rotor with the rotor holder [A], and
tighten the alternator rotor nut [B].
Special Tool - Rotor Holder: 57001-1727
Torque - Alternator Rotor Nut: 118 N·m (12.0 kgf·m, 87.0
ft·lb)
• Install:
Crankshaft Sensor (see Crankshaft Sensor Installation)
• Install:
Alternator Cover
Collar [A] and nuts [B]
Bolts [C]
• Install the removed parts.
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
ELECTRICAL SYSTEM 17-47
Charging System
Charging System Circuit (KAF620MB ∼/PB ∼)
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
17-48 ELECTRICAL SYSTEM
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plug, ignition coil, or
ignition coil lead while the engine is running, or you
could receive a severe electrical shock.
NOTICE
Do not disconnect the battery leads or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
IC igniter damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and IC igniter.
• Connect
follows.
the primary leads to the ignition coil terminals as
Front Side
Y/W Lead → (+) Mark [A]
BK/Y Lead → (–) Mark [B]
Rear Side
Y/W Lead → (+) Mark [A]
W Lead → (–) Mark [B]
• Remove:
Crankshaft Sensor Screws [A]
Crankshaft Sensor [B]
Connections
Crankshaft Sensor
Adapter Tester
Lead
Green/White ← Red → (+)
Yellow ← Black → (–)
• Turn the ignition switch on, and run the engine 4 ∼ 5 sec-
onds with the transmission gear in neutral to measure the
crankshaft sensor peak voltage.
• Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
Standard: 3.5 V or more
If the peak voltage is lower than the standard, inspect the
crankshaft sensor.
17-52 ELECTRICAL SYSTEM
Ignition System
Resistor Inspection
• Remove:
Front Cargo Compartment (see Front Cargo Compart-
ment Removal)
Band [A]
• Disconnect the resistor lead connector [B].
1. ECU Relay
2. ECU
3. Main Throttle Sensor
4. Subthrottle Sensor
5. Subthrottle Valve Actuator
6. Inlet Air Temperature Sensor
7. Ignition Switch
8. Neutral Switch
9. Engine Ground Terminal
10. Battery
11. Fuse Box 1
12. Main Fuse 30 A
13. ECU Relay Fuse 10 A
14. Ignition Coil #1
15. Ignition Coil #2
16. Crankshaft Sensor
17. Resistor (300 Ω, 1 W)
18. KAF620MC ∼/PC ∼
ELECTRICAL SYSTEM 17-55
Electric Starter System
Starter Motor Removal
• Remove:
Torque Converter Case (see Torque Converter Case Re-
moval in the Converter System chapter)
Starter Motor Leads (from Starter Motor) [A]
Starter Motor Mounting Bolts [B]
Starter Motor [C]
• Remove:
End Cover Screws [A]
End Cover [B]
17-56 ELECTRICAL SYSTEM
Electric Starter System
• 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]
ELECTRICAL SYSTEM 17-57
Electric Starter System
Starter Motor Assembly
• Grease:
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].
• Install:
Starter Clutch [A]
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 hold them with suitable plates [D]
as shown.
• Install:
Armature
• Install:
End Cover
17-58 ELECTRICAL SYSTEM
Electric Starter System
• Fit the projection [A] on the yoke [B] into the notch [C] in
the magnetic switch [D].
• Install
curely.
the magnetic switch lead and tighten the nut se-
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.
• Measure the resistance between the carbon brush and
the yoke body [B].
If there is any reading, the yoke has a short. Replace the
yoke.
Commutator Cleaning/Inspection
• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
ELECTRICAL SYSTEM 17-59
Electric Starter System
Armature Inspection
• Using the × 1 Ω range a digital meter, measure the resis-
tance 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 a digital meter, 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 a digital meter. 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.
Pinion Gear Inspection
• Turn the pinion gear by hand. It should turn counterclock-
wise freely [A], but should not turn freely clockwise [B].
If the pinion gear does not operate as it should or if there
is any worn or damaged part, replace it.
1. Starter Motor
2. Starter Circuit Relay
3. Neutral Switch
4. Battery
5. Starter Circuit Relay Fuse 30 A
6. Main Fuse 30 A
7. Ignition Switch
8. Starter Relay (KAF620ME/PE)
17-62 ELECTRICAL SYSTEM
Radiator Fan System
Radiator Fan Motor Inspection
• Disconnect the fan motor lead connectors [A].
• Using
motor.
two auxiliary 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 (–)
• Install:
Radiator Fan Breaker [A]
Holder [B]
Front [C]
Bracket [D]
ELECTRICAL SYSTEM 17-63
Radiator Fan System
Radiator Fan Circuit
1. Radiator Fan
2. Radiator Fan Breaker
3. Radiator Fan Relay
4. ECU
5. Water Temperature Sensor
6. Battery
17-64 ELECTRICAL SYSTEM
Lighting System
Headlight Beam Adjustment
• Turn the adjusting screw [A] on each headlight in or out
to adjust the headlight vertically.
Headlight Removal
• Remove:
Front Cover (see Front Cover Removal in the Frame
chapter)
Bolts [A] (KAF620M9 ∼ MB/N9/P9 ∼ PB)
Screws [A] (KAF620MC ∼/PC ∼)
Screws [B]
ELECTRICAL SYSTEM 17-65
Lighting System
Headlight Installation
○Check that the clip-nuts [A] are in place as shown in the
figure.
• Tighten:
Bolts and Screws (KAF620M9 ∼ MB/N9/P9 ∼ PB)
Screws (KAF620MC ∼/PC ∼)
• Install the front cover (see Front Cover Installation in the
Frame chapter).
• Push and turn the bulb [A] counterclockwise [B] and re-
move it.
NOTICE
Do not use bulbs rated for greater wattage than the
specified value.
• Insert the new bulb [A] by aligning its upper and lower pins
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise.
○Turn the bulb about 15°.
•○Install the tail/brake light lens.
Be careful not to overtighten the lens mounting screws.
1. Light Switch
2. Ignition Switch
3. Headlights 12 V 35 W × 2
4. Brake Light Switch
5. Battery
6. Main Fuse 30 A
7. Fuse Box 1
8. Blake/Tail Lights 12 V 21/5 W
ELECTRICAL SYSTEM 17-67
Lighting System
Indicator Light Bulb Replacement
Oil Pressure Warning Indicator Light [A]
Water Temperature Warning Indicator Light [B]
Parking Brake Indicator Light [C]
DFI Warning Indicator Light [D]
• Remove:
Light Assembly [A]
Lens [B]
• Roll the rubber [A] up and pull the bulb [B] out of the
socket.
NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb.
Do not use bulb rated for greater wattage than the
specified value.
• Install:
New Bulb
Lens [A]
Light Assembly [B]
17-68 ELECTRICAL SYSTEM
Lighting System
Indicator Light Circuit
Switch Inspection
• Using a digital meter, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
If the switch has an open or short, repair it or replace it
with a new one.
Horn Switch Connections
• Pull the fuses [A] straight out of the fuse box with needle
nose pliers.
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 [A].
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]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTICE
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
APPENDIX 18-1
Appendix
Table of Contents
Troubleshooting Guide ........................................................................................................... 18-2
Cable, Wire, and Hose Routing .............................................................................................. 18-6
18
18-2 APPENDIX
Troubleshooting Guide
NOTE Cylinder head not sufficiently tightened
○Refer to the Fuel System chapter for most down
of DFI troubleshooting guide. No valve clearance
○This is not an exhaustive list, giving every Cylinder, piston worn
possible cause for each problem listed. It Piston ring bad (worn, weak, broken, or
is meant simply as a rough guide to assist sticking)
the troubleshooting for some of the more Piston ring/groove clearance excessive
common difficulties. Cylinder head gasket damaged
Cylinder head warped
Engine Doesn’t Start, Starting Difficulty:
Valve spring broken or weak
Starter motor not rotating:
Valve not seating properly (valve bent,
Neutral switch trouble
worn, or carbon accumulation on the
Starter motor trouble
seating surface)
Battery voltage low
Poor Running at Low Speed:
Relays not contacting or operating
Spark weak:
Wiring open or shorted
Spark plug dirty, broken, or maladjusted
Ignition switch trouble
Spark plug cap or high tension wiring trou-
Fuse blown
ble
Starter motor rotating but engine doesn’t
Spark plug cap shorted or not in good con-
turn over:
tact
Starter motor trouble
Spark plug incorrect
Pinion or ring gear worn
ECU trouble
Engine won’t turn over:
Ignition coil trouble
Valve seizure
Crankshaft sensor trouble
Rocker arm seizure
Fuel/air mixture incorrect:
Cylinder, piston seizure
Air cleaner clogged, poorly sealed, or miss-
Crankshaft seizure
ing
Connecting rod small end seizure
Fuel tank air vent obstructed
Connecting rod big end seizure
Fuel pump trouble
Camshaft seizure
Compression low:
No fuel flow:
Spark plug loose
Fuel tank air vent obstructed
Cylinder head not sufficiently tightened
Fuel pump trouble
down
Fuel filter clogged
No valve clearance
Fuel line clogged
Cylinder, piston worn
Fuel pump relay trouble
Piston ring bad (worn, weak, broken, or
Engine flooded:
sticking)
Fuel level too high
Piston ring/groove clearance excessive
Float valve worn or stuck open
Cylinder head warped
Starting technique faulty
Cylinder head gasket damaged
(When flooded, crank the engine with the
Valve spring broken or weak
throttle fully opened to allow more air to
Valve not seating properly (valve bent,
reach the engine.)
worn, or carbon accumulation on the
No spark; spark weak:
seating surface)
Spark plug dirty, broken, or maladjusted
Other:
Spark plug cap or high tension wiring trou-
ECU trouble
ble
Engine oil viscosity too high
Spark plug cap not in good contact
Front final gear case oil viscosity to high
Spark plug incorrect
Drive train trouble
ECU trouble
Brake dragging
Ignition coil trouble
Resistor trouble (KAF620MC ∼/PC ∼)
Crankshaft sensor trouble
Poor Running or No Power at High Speed:
Ignition switch shorted
Firing incorrect:
Wiring shorted or open
Spark plug dirty, broken, or maladjusted
Fuse blown
Spark plug cap shorted or not in good con-
Compression Low:
tact
Spark plug loose
Spark plug incorrect
APPENDIX 18-3
Troubleshooting Guide
ECU trouble Driven pulley spring broken or weak
Ignition coil trouble Drive pulley spring broken or weak
Crankshaft sensor trouble Idle speed too high
Fuel/air mixture incorrect: Lubrication inadequate:
Air cleaner clogged, poorly sealed, or miss- Engine oil level too low
ing Engine oil poor quality or incorrect
Water or foreign matter in fuel Front final gear case overheating:
Fuel tank air vent obstructed Insufficient oil
Fuel line clogged Bevel gears maladjusted
Fuel pump trouble LSD clutch maladjusted
Compression low: Coolant incorrect:
Spark plug loose Coolant level too low
Cylinder head not sufficiently tightened Coolant deteriorated
down Thick coolant
No valve clearance Cooling system component incorrect:
Cylinder, piston worn Radiator clogged
Piston ring bad (worn, weak, broken, or Thermostat trouble
sticking) Radiator cap trouble
Piston ring/groove clearance excessive ECU trouble
Cylinder head gasket damaged Water temperature sensor trouble
Cylinder head warped Fan motor broken
Valve spring broken or weak Fan blade damaged
Valve not seating properly (valve bent, Water pump not turning
worn, or carbon accumulation on the Water pump impeller damaged
seating surface.) Over Cooling
Knocking: ECU trouble
Carbon built up in combustion chamber Thermostat trouble
Fuel poor quality or incorrect Converter Operation Faulty:
Spark plug incorrect Belt slipping:
ECU trouble Belt dirty or worn
Miscellaneous: Drive or driven pulley sheave dirty or worn
Throttle valves won’t fully open Drive 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 dirty or worn
Front final gear case oil viscosity too high Drive or driven pulley sheave dirty or worn
(KAF620M/N) Drive pulley weight doesn’t move smoothly
Drive train trouble Drive pulley movable sheave doesn’t move
Overheating: smoothly
Firing incorrect: Drive or driven pulley movable sheave bush
Spark plug dirty, broken, or maladjusted worn
Spark plug incorrect Drive pulley weight or roller worn
ECU trouble Shifting too quickly:
Fuel/air mixture incorrect: Drive pulley spring weak
Air cleaner clogged, poorly sealed, or miss- Driven pulley spring weak or incorrectly in-
ing stalled (too loose)
Compression high: Shifting too slowly:
Carbon built up in combustion chamber Belt dirty or worn
Engine load faulty: Drive or driven pulley sheave dirty or worn
Engine oil level too high Drive pulley weight doesn’t move smoothly
Engine oil viscosity too high Drive pulley movable sheave doesn’t move
Drive train trouble smoothly
Brake dragging Driven pulley spring incorrect installed (too
Converter and/or belt excessive heating: tight)
Belt dirty or worn Driven pulley movable sheave doesn’t
Drive or driven pulley sheave dirty or worn move smoothly
18-4 APPENDIX
Troubleshooting Guide
Gear Shifting Faulty: Drive or driven pulley mount loose
Doesn’t go into gear: Driven pulley shoe worn
Shift arm bent or seized Drive pulley weight or roller side washer
Gear stuck on the shaft worn
Shift cable maladjusted Drive pulley weight or roller worn
Shift cable lubrication inadequate Transmission noise:
Shift cable damaged Bearing worn
Jumps out of gear: Transmission gears worn or chipped
Shifter groove worn Metal chips jammed in gear teeth
Gear dogs worn Transmission oil insufficient
Shift arm positioning bolt spring weak or Final drive noise:
broken Bearing worn
Shift block worn Gears worn or chipped
Transmission shaft, and/or gear splines Metal chips jammed in gear teeth
worn Insufficient lubricant
Shift cable maladjusted Bevel gears maladjusted
Overshifts: Worn LSD clutch friction plate
Shift arm positioning bolt spring weak or Worn LSD clutch spring
broken Universal joint damaged
Shift cable maladjusted Abnormal Frame Noise:
Abnormal Engine Noise: Shock absorber noise:
Knocking: Shock absorber damaged
ECU trouble Brake noise:
Carbon built up in combustion chamber Brake linings overworn or worn unevenly
Fuel poor quality or incorrect Drum worn unevenly or scored
Spark plug incorrect Brake spring(s) weak or broken
Overheating Foreign matter in hub
Piston slap: Brake not properly adjusted
Cylinder/piston clearance excessive Other noise:
Cylinder, piston worn Bracket, nuts, bolts, etc. not properly
Connecting rod bent mounted or tightened
Piston pin, piston pin holes worn Exhaust Smokes Excessively:
Valve noise: White smoke:
Valve clearance incorrect Piston oil ring worn
Valve spring broken or weak Cylinder worn
Camshaft bearing worn Valve oil seal damaged
Rocker arm push rod runout excessive Valve guide worn
Other noise: Engine oil level to high
Connecting rod small end clearance exces- Black smoke:
sive Air cleaner clogged
Connecting rod big end clearance exces- Fuel level too high
sive Brown smoke:
Piston ring worn, broken or stuck Air cleaner poorly sealed or missing
Piston seizure or damaged Handling and/or Stability Unsatisfactory:
Cylinder head gasket leaking Steering wheel hard to turn:
Exhaust pipe leaking at cylinder head con- Steering shaft bearing damaged
nection Steering shaft lubrication inadequate
Crankshaft runout excessive Steering shaft bent
Engine mounts loose Steering gear assembly damaged
Crankshaft bearing worn Tire air pressure too low
Loose alternator rotor LSD clutch maladjusted
Abnormal Drive Train Noise: EPS unit trouble (KAF620M/N)
Converter noise: EPS ECU trouble (KAF620M/N)
Belt worn Noise when turning:
Drive or driven pulley sheave worn Damaged side gear or pinion (front final
Drive or driven pulley movable sheave bush gear case)
worn
APPENDIX 18-5
Troubleshooting Guide
Worn clutch friction plates (Front final gear Battery Discharged:
case) Battery faulty (e.g., plates sulphated,
Worn clutch spring (Front final gear case) shorted through sedimentation, elec-
EPS unit mount loose (KAF620M/N) trolyte level too low)
Steering wheel shakes or excessively Battery leads making poor contact
vibrates: Load excessive (e.g., bulb of excessive
Tire(s) worn wattage)
Suspension arm bushing worn Ignition switch trouble
Tie-rod joint worn Regulator/Rectifier trouble
Wheel rim warped Alternator trouble
Axle shaft bearing worn Wiring faulty
Steering wheel mount loose Battery Overcharged:
Steering bolt or nut loose Regulator/Rectifier trouble
Steering wheel pulls to one side: Battery trouble
Frame bent
Wheel misalignment
Suspension arm bent or twisted
Steering shaft bent
Steering gear assembly damaged
Front or rear tire air pressure unbalanced
Shock absorber unbalanced
Shock absorption unsatisfactory:
(Too hard)
Tire air pressure too high
Shock absorber damaged
(Too soft)
Shock absorber oil leaking
Shock absorber spring weak
Tire air pressure too low
Brake Doesn’t Hold
Air in the brake line
Brake fluid leak
Brake fluid deteriorated
Primary or secondary cup trouble
Master or wheel cylinder scratched inside
Brake not properly adjusted
Lining overworn or worn unevenly
Drum worn unevenly or scored
Oil, grease on lining and drum
Dirt, water between lining and drum
Overheated brakes
18-6 APPENDIX
Cable, Wire, and Hose Routing
1. Clamps of Frame
2. Clamps
3. Clamps of Frame
4. Battery Positive Cable
5. Battery Negative Cable
6. Brake Pipe Joint
7. 60 mm (2.36 in.)
8. Front
9. White Tape
APPENDIX 18-13
Cable, Wire, and Hose Routing
1. US Model
2. CA Model
3. Battery Positive Cable
4. Battery Negative Cable
5. Starter Relay Cable
6. Red Cap
7. Diode
8. Band
9. Band
10. Starter Relay
11. Trim
APPENDIX 18-15
Cable, Wire, and Hose Routing
1. Run the speed sensor lead to the inside of the 2WD/4WD shift cable (KAF620M/N) and differ-
ential shift cable.
2. 80 mm (3.15 in.)
3. Clamp
4. Bands
5. To Neutral Switch
6. Viewed from A
18-16 APPENDIX
Cable, Wire, and Hose Routing
1. Fuel Tank
2. Check Valve
3. Band
4. Clamps
18-22 APPENDIX
Cable, Wire, and Hose Routing
KAF620M9 ∼ MA/N9/P9 ∼ PA (other than CAL Model)
1. Front
2. Clamp
3. Clamp
4. Fuel Hose
5. Fuel Pump
APPENDIX 18-23
Cable, Wire, and Hose Routing
CAL Model and KAF620MB ∼ MC/PB ∼ PC
1. Front
2. Check Valve
3. Fuel Tank Hose (Canister ∼ Fuel Tank)
4. Canister
5. Band
6. Breather Hose
7. Purge Hose (Canister ∼ Inlet Pipe)
8. Clamps
9. Fuel Filter
10. Breather Hose (Canister ∼ Fuel Filter)
11. Fuel Hose
12. Fuel Pump
13. Viewed from A
18-24 APPENDIX
Cable, Wire, and Hose Routing
KAF620MD/PD
1. Front
2. Check Valve
3. Fuel Tank Hose (Canister ∼ Fuel Tank)
4. Canister
5. Band
6. Breather Hose
7. Purge Hose (Canister ∼ Inlet Pipe)
8. Clamps
9. Fuel Filter
10. Breather Hose (Canister ∼ Fuel Filter)
11. Fuel Hose
12. Fuel Pump
13. Viewed from A
APPENDIX 18-25
Cable, Wire, and Hose Routing
KAF620M9/N9/P9 (Early Model)
1. Right Frame
2. Right Breather Hose
3. Right Brake Drum
4. Right Brake Pipe
5. Right Parking Brake Cable
6. Front
7. Bands
8. Left Breather Hose
9. Left Frame
10. Left Parking Brake Cable
11. Left Brake Pipe
12. Left Brake Drum
MODEL APPLICATION
Year Model Beginning Frame No.
2009 KAF620M9 JK1AFCM1□9B500001
2009 KAF620N9 JK1AFCN1□9B500001
2009 KAF620P9 JK1AFCP1□9B500001
2010 KAF620MA JK1AFCM1□AB504001
2010 KAF620PA JK1AFCP1□AB501201
2011 KAF620MB JK1AFCM1□BB505601
2011 KAF620PB JK1AFCP1□BB501601
2012 KAF620MC JK1AFCM1□CB509401
2012 KAF620PC JK1AFCP1□CB502201
2013 KAF620MD JK1AFCM1□DB512401
2013 KAF620PD JK1AFCP1□DB503201
2014 KAF620ME JK1AFCM1□EB514801
2014 KAF620PE JK1AFCP1□EB503701
□:This digit in the frame number changes from one machine to another.