Kawasaki Mule 3010 Trans 4x4 - Repair, Service and Maintenance Manual

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KAWASAKI MULE 3010 TRANS 4X4 - WORKSHOP SERVICE MANUAL

- English Service Manual to UTV Kawasaki Mule 3010 Trans 4x4.

CONTENTS:

TABLES

LIST OF ABBREVIATIONS

Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
Basic Torque for General Fasteners of Engine Parts
Basic Torque for General Fasteners of Frame Parts
Throttle Pedal Free Play
Idle Speed
Water and Coolant Mixture Ratio (Recommended)
Belt Width
Wear Shoe Width
Valve Clearance (when cold)
Engine Oil
Transmission Oil
Tire Tread Depth
Standard Tire
Front Final Gear Case Oil
Brake Pedal Free Play
Brake Drum Inside Diameter
Brake Shoe Lining Thickness
Parking Brake Lever Travel
Steering Wheel Free Play
Brake Light Switch Timing
Spark Plug Gap
Throttle Link Lever Bolt/Shim Clearance
Shims
Choke Cable Free Play
Valve Closing Temperature (for reference)
Water Pump Shaft Diameter
Water Pump Shaft Bearing Inside Diameter
Radiator Cap Relief Pressure
Thermostat Valve Opening Temperature
Cylinder Compression
Cylinder Head Warp
Valve Seating Surface Outside Diameter
Valve Seating Surface Width
Valve Spring Free Length
Valve Head Thickness
Valve Stem Bend
Valve Stem Diameter
Valve Guide Inside Diameter
Valve/Guide Clearance (Wobble Method)
Rocker Shaft Diameter
Rocker Arm Inside Diameter
Rocker Arm Push Rod Runout
Belt Deflection
Spacers
Spider Wear Guide Clearance
Cover Bushing Inside Diameter [A]
Sheave Bushing Inside Diameter [B]
Spider Wear Guide Thickness [B]
Spring Free Length [A]
Sheave Bushing Inside Diameter
Spring Free Length [A]
Inner Rotor/Outer Rotor Clearance
Inner Rotor Shaft Diameter [A]
Outer Rotor Diameter [B]
Outer Rotor Width [C]
Inner Rotor Shaft Bearing Inside Diameter [A]
Outer Rotor Housing Inside Diameter [B]
Rotor Housing Depth [C]
Cam Height (Inlet)
Cam Height (Exhaust)
Camshaft Journal Diameter
Camshaft Bearing Inside Diameter
Piston Ring/Groove Clearance (Top, Second)
Piston Ring End Gap (Top, Second)
Cylinder Inside Diameter
Piston Diameter
Oversize Piston and Rings
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Clearance
Crankpin Diameter
Connecting Rod Big End Inside Diameter
Crankshaft Runout
Crankshaft Main Journal Diameter
Crankshaft Main Bearing Inside Diameter
Shift Arm Pin Diameter [A]
Shifter Block Inside Diameter [B]
Shifter Block Outside Diameter [C]
Shifter Groove Width [D]
Drive Chain 20-Link Length [B]
Shifter Block Outside Diameter [A]
Shifter Groove Width [B]
Shifter Block Outside Diameter
Shifter Groove Width
Shift Arm Pin Diameter [A]
Shifter Groove Width [B]
Toe-in of Front Wheels
Maximum Tire Air Pressure (to seat beads when cold)
Tire Air Pressure (when cold)
LSD Clutch Torque
Outside Friction Plate Thickness
Inside Friction Plate Thickness
Using Spring Scale
Using Torque Wrench
Bevel Gear Backlash
Bevel Gear Backlash
Recommended Brake Fluid
Drum Press-fitting Force (Torque)
Spring Action
Tie- rod Length (distance between boot end and locknut)
Kawasaki-recommended chargers
Battery Terminal Voltage
Terminal Voltage: 11.5 ~ less than 12.5 V
Terminal Voltage: less than 11.5 V
Regulator/Rectifier Output Voltage
Stator Coil Resistance
Ignition Coil Winding Resistance
Ignition Coil Primary Peak Voltage
Pickup Coil Resistance
Connections
Pickup Coil Peak Voltage
Carbon Brush Length
Commutator Diameter
Testing Switch
Testing Relay
Fuel Pump Leads
Fuel Pump Relay Internal Resistance (Tester Range: × 1 kO)
Radiator Fan Motor Leads
Radiator Fan Switch Resistance
Coolant Temperature Warning Light Switch Resistance

TOC

Read OWNER'S MANUAL before operating.

EMISSION CONTROL INFORMATION
 
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL ONLY)

FOREWORD

GENERAL INFORMATION

Before starting to perform an inspection service or carry out a
Battery Ground
Edges of Parts
Solvent
Cleaning vehicle before disassembly
Arrangement and Cleaning of Removed Parts
Storage of Removed Parts
Inspection
Replacement Parts
Assembly Order
Tightening Sequence
Tightening Torque
Force
Gasket, O-ring
Liquid Gasket, Locking Agent
Press
Ball Bearing and Needle Bearing
Oil Seal, Grease Seal
Circlips, Cotter Pins
Lubrication
Direction of Engine Rotation
Electrical Wires
KAF620-J1 Left Side View
KAF620-J1 Right Side View
Prefixes for Units:
Units of Temperature:

PERIODIC MAINTENANCE

The scheduled maintenance must be done in accordance with this c
The following tables list the tightening torque for the major fa
Inside Circlip Pliers:
Fuel System
Throttle Pedal Free Play Inspection
Throttle Pedal Free Play Adjustment
Full Throttle Pedal Position Adjustment
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness Inspection
Fuel Filter Inspection
Intake Chamber Water Draining
External Carburetor Mechanism Cleaning
Fuel Hoses And Connections Inspection
Fuel Hoses Replacement
Air Cleaner Element Cleaning
Air Cleaner Housing Dust and/or Water Inspection
Cooling System
Radiator Cleaning
Radiator Hose and Connection Inspection
Coolant Draining
Coolant Filling
Torque -
Coolant Filter Inspection
Converter System
Drive Belt Inspection
Converter Driven Pulley Shoe Inspection
Air Cleaner Element Cleaning/Inspection
Converter Dust or Water Draining
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Special Tool -
Torque -
Spark Arrester Cleaning
Engine Lubrication
Oil and/or Filter Change
Torque -
Oil Filter Removal
Special Tool -
Oil Filter Installation
Transmission
Transmission Oil Change
Torque -
Wheels/Tires
Wheels Nuts Tightness Inspection
Torque -
Tire Inspection
Final Drive
Front Final Gear Case Oil Change
Torque -
Torque -
Brakes
Brake Fluid Level Inspection
Brake Fluid Changing
Torque -
Brake Pedal Free Play Adjustment
Torque -
Brake Master Cylinder Cup and Dust Seal Replacement
Special Tool -
Torque -
Brake Hose and Pipe Inspection
Brake Hose and Pipe Replacement
Torque -
Brake Wear Inspection
Brake Wheel Cylinder Assembly Replacement
Torque -
Parking Brake Lever Travel Adjustment
Steering
Steering Wheel Free Play Inspection
Steering Joint Dust Boot Inspection
Frame
Seat Belt Inspection
Electrical System
Brake Light Switch Adjustment
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
General Lubrication
Pivots and Points: Lubricate with Grease.
Cables: Lubricate with Rust Inhibitor.
Cables: Lubricate with Motor Oil.
Bolts, Nuts, and Fasteners
Tightness Inspection
Nut, Bolt, and Fasteners to be checked

FUEL SYSTEM

Throttle Pedal Free Play Inspection
Throttle Pedal Free Play Adjustment
Full Throttle Pedal Position Adjustment
Throttle Cable Installation
Throttle Cable Lubrication
Throttle Cable Inspection
Control Panel Assembly Removal
Control Panel Assembly Installation
Governor Arm and Throttle Link Removal
Governor Arm Installation
Torque -
Governor Assembly Removal
Governor Assembly Installation
Governor Assembly Inspection
Throttle Link Lever Installation
Torque -
Maximum Engine Speed Inspection
Choke Cable Free Play Inspection
Choke Cable Free Play Adjustment
Choke Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Torque -
Torque -
Sealant -
Torque -
Carburetor Disassembly
Carburetor Assembly
Torque -
Carburetor Cleaning
Carburetor Inspection
Coolant Filter Cleaning
Coolant Valve Inspection
Air Cleaner Element Cleaning
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Torque -
Sealant -
Torque -
Air Cleaner Housing Dust and/or Water Inspection
Fuel Pump and Fuel Filter Removal
Fuel Pump Installation
Fuel Filter Installation
Fuel Filter Inspection
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning/Inspection

COOLING SYSTEM

Kawasaki Bond (Silicone Sealant):
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pump Removal
Water Pump Installation
Torque -
Water Pump Inspection
Radiator Removal
Radiator Inspection
Radiator Cleaning
The radiator cap at the reservoir tank has the pressure relief v
Radiator Cap Inspection
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Hose and Pipe Installation
Hose Inspection
Radiator Fan Switch, Coolant Temperature Warning Light Switch Re
Radiator Fan Switch, Coolant Temperature Warning Light Switch In
Sealant -
Torque -
Radiator Fan Switch, Coolant Temperature Warning Light Switch In

ENGINE TOP END

Outside Circlip Pliers:
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Torque -
Torque -
Cylinder Head Disassembly and Assembly (Valve Mechanism Removal
Special Tool -
Cylinder Head Warp
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Seat Inspection
Valve Seat Repair
Special Tools -
Special Tools -
Valve Spring Free Length
Valve Head Thickness
Valve Stem Bend
Valve Stem Diameter
Valve Guide Inside Diameter
Measuring Valve/Guide Clearance (Wobble Method)
Rocker Arm/Shaft Wear
Rocker Arm Push Rod Inspection
Exhaust Pipe Removal
Muffler Removal
Exhaust Pipe and Muffler Installation
Exhaust Pipe and Muffler Inspection
Spark Arrester Cleaning

CONVERTER SYSTEM

Outside Circlip Pliers:
Air Cleaner Housing Removal
Air Cleaner Element Removal
Air Cleaner Element Cleaning/Inspection
Torque Converter Removal
Special Tool -
Torque Converter Installation
Torque -
Torque -
Torque Converter Case Removal
Drive Belt Removal
Drive Belt Installation
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Torque -
Drive Belt Inspection
Drive Pulley Disassembly
Special Tool -
Special Tool -
Drive Pulley Assembly
Torque -
Special Tool -
Torque -
Torque -
Spider/Wear Guide Clearance Adjustment
Drive Pulley Inspection
Bushing Installation
Driven Pulley Disassembly
Special Tools -
Special Tool -
Driven Pulley Assembly
Torque -
Special Tools -
Special Tool -
Driven Pulley Inspection
Bushing Installation

ENGINE LUBRICATION SYSTEM

Oil Filter Wrench:

WARNING

Oil Level Inspection
Oil and/or Filter Change
Oil Filter Removal
Oil Filter Installation
Oil Pump and Relief Valve Removal
Oil Pump and Relief Valve Installation
Oil Pump and Relief Valve Inspection
Oil Screen Removal
Oil Screen Installation
Oil Screen Cleaning/Inspection
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Sealant -
Torque -

ENGINE REMOVAL/INSTALLATION

Engine Removal
Engine Installation
Torque -

ENGINE BOTTOM END

Piston Pin Puller Assembly:
Crankcase Cover Removal
Crankcase Cover Installation
Torque -
Camshaft Removal
Camshaft Installation
Camshaft Inspection
Cam Wear
Camshaft Bearing/Journal Wear
Piston Removal
Special Tool -
Piston Installation
Special Tools -
Torque -
Piston Ring, Piston Ring Groove Wear
Piston Ring End Gap
Cylinder Inside Diameter
Piston Diameter
Boring, Honing
Connecting Rod Removal
Connecting Rod Installation
Crankshaft Removal
Crankshaft Installation
Crankshaft Cleaning
Connecting Rod Bend/Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Wear
Torque -
Torque -
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Breather Valve Removal
Breather Valve Installation
Breather Valve Inspection

RANSMISSION

Outside Circlip Pliers:

CAUTION

Transmission Oil Level Inspection
Transmission Oil Change
Transmission Case Removal
Transmission Case Installation
Torque -
Transmission Case Splitting
Transmission Case Assembly
Sealant -
Torque -
Transmission and Hi/Low Shift Cables Installation
Shift Lever Position Inspection
Shift Lever Position Adjustment
Transmission Shift Cable Inspection
Transmission Removal
Special Tool -
Special Tool -
Transmission Installation
Torque -
Transmission and Shift Mechanism Inspection
Hi/Low Shift Cable Installation
Hi/Low Shift Cable Inspection
Hi/Low Gear and Shift Mechanism Removal
Special Tool -
Hi/Low Gear and Shift Mechanism Installation
Torque -
Hi/Low Gear and Shift Mechanism Inspection
2WD/4WD Shift Cable Adjustment
2WD/4WD Shift Cable Lubrication
2WD/4WD Shift Cable Inspection
2WD/4WD Shift Mechanism Removal
Special Tool -
2WD/4WD Shift Mechanism Installation
Torque -
2WD/4WD Shift Mechanism Inspection
Differential Shift Cable Adjustment
Differential Shift Cable Lubrication
Differential Shift Cable Inspection
Differential Shift Mechanism Removal
Differential Shift Mechanism Installation
Torque -
Differential Shift Mechanism Inspection
Differential Gear Removal
Differential Gear Installation
Torque -
Differential Gear Inspection
Bearing Replacement
Special Tools -
Special Tool -
Torque -
Special Tool -
Ball Bearing Inspection
Needle Bearing Inspection
Oil Seal Inspection

WHEELS/TIRES

Toe-in is the amount that the front wheels are closer together i
Toe-in Adjustment
Torque -
Wheel Removal
Wheel Installation
Torque -
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tire Removal
Tire Installation
Tire Inspection

FINAL DRIVE

Bearing Puller:
Front Final Gear Case Oil Level Inspection
Torque -
Front Final Gear Case Oil Change
Front Final Gear Case Removal
Front Final Gear Case Installation
Torque -
Front Final Gear Case Disassembly
Front Final Gear Case Assembly
Torque -
Differential Unit and Ring Gear Disassembly
Differential Unit and Ring Gear Assembly
Torque -
LSD Clutch Torque Inspection
LSD Clutch Plate Inspection
Pinion Gear Unit Disassembly
Special Tools -
Special Tool -
Pinion Gear Unit Assembly
Torque -
Front Final Bevel Gear Adjustment
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Bevel Gear Inspection
Differential Gear Inspection
Tapered Roller Bearing Inspection
Ball Bearing Inspection
Oil Seal Inspection
Bevel Gear Case Removal
Bevel Gear Case Installation
Torque -
Bevel Gear Case Disassembly
Special Tools -
Special Tools -
Special Tool -
Special Tool -
Special Tools -
Bevel Gear Case Assembly
Torque -
Drive Bevel Gear Removal
Special Tool -
Drive Bevel Gear Installation
Torque -
Bevel Gear Adjustment
Special Tool -
Bevel Gear Inspection
Ball Bearing Inspection
Oil Seal Inspection
Damper Inspection
Propeller Shaft Removal
Propeller Shaft Installation
Propeller Shaft Inspection
Front Axle Removal
Front Axle Installation
Torque -
Rear Drive Shaft and Axle Removal
Rear Drive Shaft and Axle Installation
Drive Shaft and Axle Inspection
Dust Boot Inspection
Front Axle Joint Boot Replacement
Special Tool -
Special Tool -
Special Tool -
Ball Bearing Inspection
Grease Seal Inspection

BRAKES

Inside Circlip Pliers:
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Changing
Brake Line Air Bleeding
Torque -
Brake Pedal Free Play Adjustment
Master Cylinder Removal
Master Cylinder Installation
Torque -
Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection
Brake Hose and Pipe Inspection
Brake Hose and Pipe Replacement
Brake Drum Removal
Special Tools -
Brake Drum Installation
Special Tools -
Torque -
Brake Drum Wear
Brake Panel Removal
Brake Panel Installation
Torque -
Wheel Cylinder Assembly
Wheel Cylinder Inspection
Brake Shoe Lining Wear
Brake Shoe Spring Inspection
Parking Brake Lever Travel Adjustment
Parking Brake Cable Lubrication
Parking Brake Cable Inspection
SUSPENSION
Steering Stem Nut Wrench:
Strut (Front Shock Absorber) Removal
Strut (Front Shock Absorber) Installation
Torque -
Strut Spring Replacement
Torque -
Rear Shock Absorber Preload Adjustment
Special Tool -
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Torque -
Shock Absorber Inspection
Front Suspension Arm Removal
Front Suspension Arm Installation
Torque -
Front Suspension Arm Inspection
Leaf Spring Removal
Leaf Spring Installation
Torque -
Torque -
Leaf Spring Inspection

STEERING

Steering Wheel Position Adjustment
Steering Wheel Free Play Inspection
Steering Wheel Centering
Torque -
Steering Wheel and Steering Shaft Removal
Steering Wheel and Main Shaft Installation
Torque -
Steering Gear Assembly Removal
Steering Gear Assembly Installation
Torque -
Steering Gear Preload Adjustment
Torque -
Tie-rod Length Adjustment
Torque -
Steering Joint Dust Boot Inspection
Steering Knuckle Removal
Steering Knuckle Installation
Torque -
FRAME
Front Seat Removal
Front Seat Installation
Rear Seat Removal
Rear Seat Installation
Seat Belt Removal
Seat Belt Installation
Torque -
Torque -
Control Panel Removal
Glove Compartment Removal
Front Cargo Hood Removal
Front Cargo Compartment Removal
Cargo Bed Removal
Cargo Bed Installation
Front Bar Removal
Front Bar Installation
Torque -




Rear Bar Removal
Rear Bar Installation
Torque -
Center Bar Removal
Center Bar Installation
Torque -
Cargo Bed Latch Position Inspection
Cargo Bed Latch Position Adjustment
Front Cover Removal
Front Fender Removal
Radiator Side Cover Removal
Radiator Side Cover Installation
Radiator Side Cover Flap Removal
Floor Center Panel Removal
Rear End Sub-frame Removal
Rear End Sub-frame Installation
Torque -

ELECTRICAL SYSTEM

Crankcase Splitting Tool Assembly:
Horn [A]
There are a number of important precautions that are musts when
Battery Removal
Battery Installation
Torque -
Battery Activation
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Alternator Rotor and Stator Removal
Special Tool -
Alternator Rotor and Stator Installation
Torque -
Charging System Operational Inspection
Stator Coil Resistance
Regulator/Rectifier Inspection
Charging System Circuit

WARNING

Spark Plug Removal/Installation

Torque -
Spark Plug Gap Inspection
Spark Plug Cleaning/Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Ignition Coil Primary Peak Voltage Inspection
Special Tools -
Pickup Coil Removal
Pickup Coil Inspection
Pickup Coil Peak Voltage Inspection
Special Tool -
Ignition System Inspection
Ignition System Circuit
Starter Motor Removal
Starter Motor Installation
Torque -
Starter Motor Disassembly
Starter Motor Assembly
Carbon Brush Inspection
Yoke Inspection
Brush Plate Inspection
Commutator Cleaning/Inspection
Armature Inspection
Pinion Gear Inspection
Starter Switch Inspection
Starter Circuit Relay Inspection
Electric Starter Circuit
The fuel pump does not operate when the ignition switch is turne
Fuel Pump Operational Inspection
Fuel Pump Relay Internal Resistance
Fuel Pump and Relay Circuit
Radiator Fan Circuit Inspection
Radiator Fan Motor Inspection
Radiator Fan Circuit
Headlight Beam Adjustment

Headlight Bulb Replacement
Tail/Brake Light Replacement
Lighting System Circuit
Brake Light Switch Adjustment
Switch Inspection
Radiator Fan Switch Inspection
Coolant Temperature Warning Light Switch Inspection
Fuse Removal
Fuse Installation
Fuse Inspection
Wiring Inspection

APPENDIX

NOTE

Engine Doesn't Start, Starting Difficulty:
Starter motor not rotating:
Starter motor rotating but engine doesn't turn over:
Engine won't turn over:
No fuel flow:
Engine flooded:

No spark; spark weak:
Compression Low:
Poor Running at Low Speed:
Spark weak:
Fuel/air mixture incorrect:
Compression low:
Other:
Poor Running or No Power at High Speed:
Firing incorrect:
Fuel/air mixture incorrect:
Compression low:
Knocking:
Miscellaneous:
Overheating:
Firing incorrect:
Fuel/air mixture incorrect:
Compression high:
Engine load faulty:
Converter and/or belt excessive heating:
Lubrication inadequate:
Front final gear case overheating:

Coolant incorrect:
Cooling system component incorrect:
Over Cooling
Converter Operation Faulty:
Belt slipping:
Converter engagement speed too low:
Converter engagement speed too high:
Shifting too quickly:
Shifting too slowly:
Gear Shifting Faulty:
Doesn't go into gear:
Jumps out of gear:
Overshifts:
Abnormal Engine Noise:
Knocking:
Piston slap:
Valve noise:
Other noise:
Abnormal Drive Train Noise:
Converter noise:
Transmission noise:
Final drive noise:
Abnormal Frame Noise:
Shock absorber noise:
Brake noise:
Other noise:
Exhaust Smokes Excessively:
White smoke:
Black smoke:
Brown smoke:
Handling and/or Stability Unsatisfactory:
Steering wheel hard to turn:
Noise when turning:
Steering wheel shakes or excessively vibrates:
Steering wheel pulls to one side:
Shock absorption unsatisfactory:
Brake Doesn't Hold
Battery Discharged:
Battery Overcharged: