How To Repair Brakes On 2005 Kawasaki Mule 3010? Written By Woodside Towery Saturday, 25 December 2021 Add Comment Edit Download or browse on-line these Service Manual for Kawasaki MULE3010 Utility Vehicle. Summary of Contents [Page 1] Kawasaki MULE3010 Manual MULE3010 MULE3020 MULE3000 Utility Vehicle Service Manual ... [Page 3] Kawasaki MULE3010 Manual This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectio... [Page 5] Kawasaki MULE3010 Manual MULE3010 MULE3020 MULE3000 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 ... [Page 6] Kawasaki MULE3010 Manual LIST OF ABBREVIATIONS A ampere(s) lb pounds(s) ABDC after b ottom 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... [Page 7] Kawasaki MULE3010 Manual EMISSION CONTROL INFORMATION 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 Unit... [Page 8] Kawasaki MULE3010 Manual NOTE ○ The phrase "remove or render inoperative any device or ele men t of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rende ring inoperative of de- vices or elements of design... [Page 9] Kawasaki MULE3010 Manual Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to m ake it useful to the owner who de- sires to perform his own basic maintenance and rep... [Page 10] Kawasaki MULE3010 Manual NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con - venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step i... [Page 11] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification.............................. [Page 12] Kawasaki MULE3010 Manual 1-2 G ENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a d isassembly and reassembly oper- ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra- tions,... [Page 13] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-3 Before Servicing (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needl... [Page 14] Kawasaki MULE3010 Manual 1-4 G ENERAL INFORMATION Before Servicing (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abra... [Page 15] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-5 Model Identification KAF620-E1 Left Sid e View KAF620-E1 Right Side View ... [Page 16] Kawasaki MULE3010 Manual 1-6 G ENERAL INFORMATION Model Identification KAF620-G1 Left Sid e View KAF620-G1 Right Side View ... [Page 17] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-7 General Specifications Items KAF620-E1/F1/G1/H1 ∼ KAF620-E5/G5/H3, E6F/G6F/H6F ∼ Dimensions Overall Length 2 861 mm (112.64 in.) Overall Width 1 460 mm (57.48 in.) Overall Height 1 936 mm (76.22 in.), (F) 1 900 mm (74.80 i... [Page 18] Kawasaki MULE3010 Manual 1-8 G ENERAL INFORMATION General Specifications Items KAF620-E1/F1/G1/H1 ∼ KAF620-E5/G5/H3, E6F/G6F/H6F ∼ 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 D... [Page 19] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-9 General Specifications Items KAF620-E1/F1/G1/H1 ∼ KAF620-E5/G5/H3, E6F/G6F/H6F ∼ Transmission Oil: Type API GL-6 Hypoid gear oil, SAE 90 (above 5 °C, 41°F) or SAE 80 (below 5°C, 41°F) Capacity 2.5 L (2.6 US qt), (F, G)... [Page 20] Kawasaki MULE3010 Manual 1-10 GENERAL INFORMATION 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 ... [Page 21] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-11 Periodic Maintenance Chart FREQUENCY Whichever comes first First Service Regular Service → ↓ OPERATION Every After 50 h, or 1 000 km of use Every 250 h, or 5 000 km of use Every 500 h, or 10 000 km of use CHASSIS Steering... [Page 22] Kawasaki MULE3010 Manual 1-12 GENERAL INFORMATION 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. Letters used in the "Remarks" column mean: L... [Page 23] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-13 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Cooling Fan Cover Bolts 8.8 0.9 78 in·lb Engine Lubrication System Engine Oil D rain Plug (M14) 22 2.2 16 Engine Oil D rain Plug (M16) 25 2.5 18 Oil Pressur... [Page 24] Kawasaki MULE3010 Manual 1-14 GENERAL INFORMATION Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Bevel Gear Case (KAF620E/H): Bevel Gear Case Bolts 22 2.2 16 Driven Gear Shaft Nut 110 11 80 L Bearing Holder 120 12 87 L Housing Locknut 120 12 87 L Bevel G... [Page 25] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-15 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Front Bar Mounting Bolts (Upper) 44 4.5 33 Rear Bar Mounting Bolts And Nuts 44 4.5 33 Rear End Sub-frame Mounting B olts 44 4.5 33 Hood Latch Lever Mounting ... [Page 26] Kawasaki MULE3010 Manual 1-16 GENERAL INFORMATION Special Tools, Sealant Bearing Puller: 57001-135 Inside Circlip Pliers: 57001-143 Outside Circlip Pliers: 57001-144 Piston Pin Puller Assembly: 57001-910 Oil Seal & Bearing Remover: 57001-1058 Piston Ring Compressor Grip:... [Page 27] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-17 Special Tools, Sealant Valve Seat Cutter Holder Bar: 57001-1128 Bearing Driver Set: 57001-1129 Valve Seat Cutter, 45° - 30: 57001-1187 Hexagon Wrench, Hex 32: 57001-1194 Valve Seat Cutter, 32° - 33: 57001-1199 Rotor Puller,... [Page 28] Kawasaki MULE3010 Manual 1-18 GENERAL INFORMATION Special Tools, Sealant Pinion Gear Holder, m1.0: 57001-1281 Socket Wrench: 57001-1283 Pinion Gear Holder, m1.0: 57001-1285 Hexagon Wrench, Hex 40: 57001-1324 Brake Drum Holder: 57001-1325 Brake Drum Remover Nuts: 57001-1326 V... [Page 29] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-19 Special Tools, Sealant Drive Pulley Wrench: 57001-1411 Drive & Driven Pulley Holder: 57001-1412 Peak Voltage Adapter: 57001-1415 Drive Pulley Puller Bolt: 57001-1429 Needle Adapter Set: 57001-1457 Driven Pull ey Holder: 5... [Page 30] Kawasaki MULE3010 Manual 1-20 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Headlight Lead 2. Main Harness 3. Band (Do not tighten band on wire connector joint.) 4. Black/Yellow Lead 5. Red/Black Lead 6. Red/Yellow Lead ... [Page 31] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-21 Cable, Wire, and Hose Routing 1. Water Temperature Warning/Parking Brake Indicator Lights 2. Oil Pressure Warning Indicator Light Lead (for Option) 3. Power Outlet Connector 4. Ignition Switch 5. Hour Meter 6. Speedometer Cab... [Page 32] Kawasaki MULE3010 Manual 1-22 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Radiator Fan Motor 2. Radiator Fan Motor Lead 3. Radiator Fan Switch 4. Horn Lead 5. Front Final Gear Case Breather Hose 6. Radiator Fan Motor Tube 7. Brake Light Switch 8. Speedometer Cable ... [Page 33] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-23 Cable, Wire, and Hose Routing 1. Brake Master Cylinder 2. Keep hose away from steering intermediate shaft. 3. Install clamp in this direction. 4. Brake Hose (Left) ... [Page 34] Kawasaki MULE3010 Manual 1-24 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Main Harness 2. Choke Cable 3. Differential Shift Cable 4. Brake Light Switch 5. Radiator Fan Motor Tube 6. Throttle Cable 7. Transmission Shift Cable 8. 2WD/4WD Shift Cable (KAF620E/H) 9. Hi... [Page 35] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-25 Cable, Wire, and Hose Routing 1. Ignition Switch Lead 2. Headlight Lead (Left) 3. Headlight Lead (Right) 4. Main Harness 5. Band 6. 110 mm (4.3 in.) 7. 80 mm (3.2 in.) 8. 170 mm (6.7 in.) 9. 300 mm (11.8 in.) 10. 140 mm (5.5 ... [Page 36] Kawasaki MULE3010 Manual 1-26 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Breather Tube 2. Brake Hose 3. Brake Pipe 4. Clamp 5. Band ... [Page 37] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-27 Cable, Wire, and Hose Routing 1. Front Brake Master Cylinder 2. Brake Hose 3. Harness 4. Clamp 5. Band 6. Parking Brake Lever Boot (KAF620-E4/G4/H2 ∼) ... [Page 38] Kawasaki MULE3010 Manual 1-28 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Right Brake Drum 2. Right Bracket 3. Breather Tube 4. Brake Pipe 5. Brake Cable 6. Left Brake Drum 7. Left Bracket 8. Screw 9. Clamp 10. Band 11. Fuel Hose 12. Breather Hose (run above the fu... [Page 39] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing 1. Differential Shift Cable 2. Throttle Cable 3. Transmission Shift Cable 4. Hi/Low Shift Cable 5. 2WD/4WD Shift Cable (KAF620E/H) 6. Choke Cable 7. Main Harness 8. Parking Brake Cable 9. Left Pa... [Page 40] Kawasaki MULE3010 Manual 1-30 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Main Harness 2. Position Mark (White Tape) 3. Brake Pipe Joint 4. Accessory Connectors 5. Headlight Lead (Left) 6. Ground Lead (Steering Gear Assembly) 7. Radiator Fan Motor Lead 8. Radiator ... [Page 41] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-31 Cable, Wire, and Hose Routing 1. Steering Main Shaft 2. Fuel Pump 3. Cover 4. Brake/Tail Light Lead 5. Neutral Switch Lead 6. Parking Brake Switch Lead 7. Battery (+) Cable 8. Battery (–) Cable 9. Ground Lead (Frame) 10. Ba... [Page 42] Kawasaki MULE3010 Manual 1-32 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Fuse Box 2. Parking Brake Switch Lead 3. Starter Circuit Relay 4. Ground Lead (Frame) 5. Starter Motor Cable 6. Ground Lead (Engine) 7. Plug 8. Band 9. Radiator Fan Breaker (KAF620E7F/G7F/H7F... [Page 43] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-33 Cable, Wire, and Hose Routing 1. Fuel Pump 2. Reverse Light Switch Lead (European Model) 3. Neutral Switch Lead 4. Cover 5. Clamp 6. Band 7. 80 mm (3.2 in.) 8. 100 m m (3.9 in.) 9. 120 m m (4.7 in.) 10. 160 mm (6.3 in.) 11. 2... [Page 44] Kawasaki MULE3010 Manual 1-34 GENERAL INFORMATION Cable, Wire, a nd Hose Routing 1. Horn Button 2. Horn Switch Contact 3. Ground Lead 4. to Main Harness 5. Band 6. Front 7. Installation condition of horn switch contact ... [Page 45] Kawasaki MULE3010 Manual GENERAL INFORMATION 1-35 Cable, Wire, and Hose Routing 1. Speedometer Cable 2. Clamp the speedometer cable with other cables, harness and brake pipe. 3. Clamp the speedometer cable with other cables. 4. Clamp the speedometer cable with the parking br... [Page 46] Kawasaki MULE3010 Manual 1-36 GENERAL INFORMATION Cable, Wire, a nd Hose Routing KAF620-E4/H2 ∼ 1. Diff Lock Cable 2. Cable Bracket 3. 100 mm (3.9 in.) 4. Cable Clamp 5. 2WD/4WD Shift Cable ... [Page 47] Kawasaki MULE3010 Manual FUEL SYSTEM 2-1 2 Fuel System Table of Contents Exploded View................................... 2-2 Specifications .................................... 2-4 Throttle Pedal and Cable................... 2-5 Throttle Pedal Free Play Inspection............. [Page 48] Kawasaki MULE3010 Manual 2-2 FUEL SYST EM Exploded View T1: 20 N·m (2.0 kgf·m, 14 ft·lb) G: Apply grease. ... [Page 49] Kawasaki MULE3010 Manual FUEL SYSTEM 2-3 Exploded View 1. Fuel Tank Holders (KAF620-E4/G4/H2 ∼) T1. 2.0 N·m (0.2 kgf·m, 18 in·lb) T2: 2.9 N·m (0.3 kgf·m, 26 in·lb) T3: 4.9 N·m (0.5 kgf·m, 43 in·lb) T4: 7.4 N·m (0.75 kgf·m, 65 in·lb) T5: 8.8 N·m (0.9 kgf·m, 78... [Page 50] Kawasaki MULE3010 Manual 2-4 FUEL SYST EM Specifications Item Standard Service Limit Throttle Pedal and Cable Throttle Pedal Free Pla y 5 ∼ 10 mm (0.2 ∼ 0.4 in.) ––– Governer Link Mechanism Throttle L ink Lever Bolt/Shim Clearance 0.05 ∼ 0.3 m m (0.002 ∼ 0.012 ... [Page 51] Kawasaki MULE3010 Manual FUEL SYSTEM 2-5 Throttle Pedal and Cable Throttle Pedal Free Play Inspe c tion • Check that the throttle pedal moves smoothly from full open to close. If the throttle pedal does not return properly, lubricate the throttle c able. • Check the thro... [Page 52] Kawasaki MULE3010 Manual 2-6 FUEL SYST EM Throttle Pedal and Cable Throttle Cable Installation • Route the throttle cable correctly (see General Informa- tion chapter). • Adjust: Throttle Pedal Free Play Adjustment WARNING Operation with incorrectly routed or improperly ... [Page 53] Kawasaki MULE3010 Manual FUEL SYSTEM 2-7 Governor Link Mechanism Control Panel Assembly Removal • Remove: Cargo Bed (raise up) • Drill out the pop rivets [A] holding the control panel as- sembly shroud [B] with a drill bit o f the 5 mm (0.02 in.) diameter. ○ Drill only... [Page 54] Kawasaki MULE3010 Manual 2-8 FUEL SYST EM Governor Link Mechanism 1. Governor Arm 2. Pivot Arm 3. Link 4. Hole 5. Turn the pivot arm. 6. Turn the governor arm. 7. Carburetor Throttle Full Open 8. Throttle Full Open 9. Governor Arm Clamp Nut 10. Pin 11. Front-Reverse Shift Ca... [Page 55] Kawasaki MULE3010 Manual FUEL SYSTEM 2-9 Governor Link Mechanism • Turn the bushings [A] counterclockwise until fitting on the link with click [B]. • Fit the 4 bosses on the intake pipe of the engine with the carburetor cover after pass the link i nto the hole of the car... [Page 56] Kawasaki MULE3010 Manual 2-10 FUEL SYSTEM Governor Link Mechanism Governor Arm and Throttle Link Removal • Remove: Cargo Bed (raise up) Control Panel Assembly Shroud Carburetor Cover Bolts [A] Carburetor Cover [B] • Remove: Throttle Link [A] Governer Arm [B] Governor Arm... [Page 57] Kawasaki MULE3010 Manual FUEL SYSTEM 2-11 Governor Link Mechanism Governor Assembly Removal • Remove: Transmission Case (split) Governor Arm Governor Shaft Snap Pin [A] Governor Shaft [B] Washer (thin) [C] Washer (thick) [D] • Remove the governor assembly [A] with the sl... [Page 58] Kawasaki MULE3010 Manual 2-12 FUEL SYSTEM Governor Link Mechanism Throttle Link Lever I nstallation • Measure the clearance [A] between the seating surface of the bolt head and shims. Throttl e L ink Lever Bolt/Shim Clearan ce Standard: 0.05 ∼ 0.3 mm (0.002 ∼ 0.012 in.... [Page 59] Kawasaki MULE3010 Manual FUEL SYSTEM 2-13 Choke Cable Choke Cable Free Play Inspection • Push in the c hoke knob all the way. • Check the choke cable free play [A]. ○ Determine the amount of free play at the choke knob. Pull the choke knob until the starter lever [B] o... [Page 60] Kawasaki MULE3010 Manual 2-14 FUEL SYSTEM Choke Cable Choke Cable Inspection • With the choke cable disconnected at both ends, the ca- ble should move freely [A] within the cable housing. If the cable does not move freely after lubricating, if the cable is frayed, or if th... [Page 61] Kawasaki MULE3010 Manual FUEL SYSTEM 2-15 Carburetor Idle Speed Inspection • Start the engine and warm it up thoroughly. • Tilt up the cargo bed. • Check the idle speed with a tachometer. If the idle speed is out of the specified range, adjust it. Idle Speed Standard: ... [Page 62] Kawasaki MULE3010 Manual 2-16 FUEL SYSTEM Carburetor Carburetor Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flam... [Page 63] Kawasaki MULE3010 Manual FUEL SYSTEM 2-17 Carburetor Carburetor Installation • Install: Pins [A] New Gasket [B] Choke Link [C] Carburetor • Install: Pins [A] New Gasket [B] • Install: Chamber Case [A] Carburetor Mounting Bolts [B] • Tighten: Torque - Carburetor Mount... [Page 64] Kawasaki MULE3010 Manual 2-18 FUEL SYSTEM Carburetor • Remove: Carburetor (see Carburetor Removal) Float Bowl Screws [A] Float Bowl [B] • Remove: Pin [A] Float [B] • Remove: Pilot Jets [A] • Remove: Main Jets [A] Carburetor Assembly • Tighten: Torque - Float Bow l ... [Page 65] Kawasaki MULE3010 Manual FUEL SYSTEM 2-19 Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the dange... [Page 66] Kawasaki MULE3010 Manual 2-20 FUEL SYSTEM Carburetor • Check that the gasket [A] on the float bowl is in good condition. If the gasket is not in good condition, replace it. • Check the float [A] for cracks. If there are any cracks, replace the float. NOTE ○ Float heigh... [Page 67] Kawasaki MULE3010 Manual FUEL SYSTEM 2-21 Air Cleaner Air Cleaner Element Cleaning • Unlock the clamps [A]. • Remove: Air Cleaner Cover [B] • Remove: Element [A] • Clean the element by tapping gently with the handle end of a screwdriver. If the element is very dirty ... [Page 68] Kawasaki MULE3010 Manual 2-22 FUEL SYSTEM Air Cleaner Air Cleaner Housing Dust and/or Water Inspection • Push open the drain tube [A] on the bottom of the air cleaner housing. ... [Page 69] Kawasaki MULE3010 Manual FUEL SYSTEM 2-23 Fuel Pump and Fuel Filter Fuel Pump and Fuel Filter Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated an... [Page 70] Kawasaki MULE3010 Manual 2-24 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Fuel is extremely flammable and can be explosive under certain conditions. Turn the main switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;... [Page 71] Kawasaki MULE3010 Manual COOLING SYSTEM 3-1 3 Cooling System Table of Contents Exploded View........................................................................................................................ 3-2 Specifications .............................................. [Page 72] Kawasaki MULE3010 Manual 3-2 COOLING SYSTEM Exploded View T1: 4.4 N·m (0.45 kgf·m, 39 in·lb) T2: 8.8 N·m (0.9 kgf·m, 78 in·lb) T3: 17 N·m (1.7 kgf·m, 12 ft·lb) T4: 23 N·m (2.3 kgf·m, 17 ft·lb) T5: 25 N·m (2.5 kgf·m, 18 ft·lb) S: Follow specified tightening seq... [Page 73] Kawasaki MULE3010 Manual COOLING SYSTEM 3-3 Specifications Item Standard Service Limit Coolant Type Permanent type of antifreeze ––– (Soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green ––– Mi... [Page 74] Kawasaki MULE3010 Manual 3-4 COOLING SYSTEM Flow Chart 1. Air Bleeder Bolt (Intake Manifold) 2. Air Bleeder Bolt (Water Pipe) 3. Thermostat 4. Radiator Cap 5. Reservoir Tank ... [Page 75] Kawasaki MULE3010 Manual COOLING SYSTEM 3-5 Flow Chart 1. Filter 2. Thermo Valve 3. White Mark 4. Coolant Inlet 5. Coolant Outlet 6. Level the tube to the inlet pipe. 7. Do not bulge the tube as a dotted line. 8. Face the projection on the valve body to the carburetor. ... [Page 76] Kawasaki MULE3010 Manual 3-6 COOLING SYSTEM Coolant Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room of ambi- ent temperature). CAUTION Do not check the level through the coolant filler by removing the radiator cap. If the cap is removed, the c... [Page 77] Kawasaki MULE3010 Manual COOLING SYSTEM 3-7 Coolant • Remove: Coolant Drain Plug [A] at Front Cylinder ○ Place a container under the drain plug. • Remove: Torque Converter Coolant Drain Plug [A] at Rear Cylinder ○ Place a container under the drain plug. • Remove: F... [Page 78] Kawasaki MULE3010 Manual 3-8 COOLING SYSTEM Coolant Coolant Filling • Tighten the drain plugs. Torque - Coolant Drain Plugs (Cylinder): 17 N·m (1.7 kgf·m, 12 ft·lb) • Remove: Radiator Cap Air Bleeder Bolts [A] • Pour the coolant slowly so that the air in the engine ... [Page 79] Kawasaki MULE3010 Manual COOLING SYSTEM 3-9 Coolant • Bleed the air from the cooling system as follows. ○ Start the engine and run it until no more air bubbles can be seen in the coolant in the reservoir tank (less than five minutes). ○ Tap the radiator hoses to force ... [Page 80] Kawasaki MULE3010 Manual 3-10 COOLING SYSTEM Water Pump Water Pump Removal • Remove: Torque Converter Coolant (drain) Radiator Hoses [A] Water Pump Cover Bolts [B] Water Pump Cover [C] • Remove: Water Pump Housing Bolt [A] Water Pump Housing [B] • Remove: Water Pump Dr... [Page 81] Kawasaki MULE3010 Manual COOLING SYSTEM 3-11 Water Pump • Remove: Mechanical Seal [A] Oil Seal [B] Water Pump Installation • Clean the sliding surface of a new mechanical seal with a high-flash point solvent, and apply a little coolant to the sliding surface to give the ... [Page 82] Kawasaki MULE3010 Manual 3-12 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the water pump body for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the pass... [Page 83] Kawasaki MULE3010 Manual COOLING SYSTEM 3-13 Radiator and Radiator Fan Radiator Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RA DIATOR FAN CONNEC... [Page 84] Kawasaki MULE3010 Manual 3-14 COOLING SYSTEM Radiator and Radiator Fan 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... [Page 85] Kawasaki MULE3010 Manual COOLING SYSTEM 3-15 Radiator Cap The radiator cap at the reservoir tank has the pressure relief valve, and must be inspected. The cap at the radiator has no valve. CAUTION Do not change the positions of the radiator cap at the reservoir tank and the ... [Page 86] Kawasaki MULE3010 Manual 3-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant (drain) Hose [A] • Remove: Thermostat Housing Cap Bolts [A] Thermostat Housing Cap [B] Thermostat Installation • Install the thermostat [A] so t hat the jiggle valve [B] is on ... [Page 87] Kawasaki MULE3010 Manual COOLING SYSTEM 3-17 Thermostat • To check valve opening temperature, suspend the ther- mostat in a container of water and raise the temperature of the water. If the measurement is out of the specified range, replace the thermostat. Thermostat Valve... [Page 88] Kawasaki MULE3010 Manual 3-18 COOLING SYSTEM Hoses and Pipes HoseandPipeInstallation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible... [Page 89] Kawasaki MULE3010 Manual COOLING SYSTEM 3-19 Radiator Fan Switch, Coolant Temperature Warning Light Switch Radiator Fan Switch, Coolant Temperature Warning Light Switch Removal CAUTION The fan switch or the coolant temperature warning light switch should never be allowed to ... [Page 91] Kawasaki MULE3010 Manual ENGINE TOP END 4-1 4 Engine Top End Table of Contents Exploded View........................................................................................................................ 4-2 Specifications .............................................. [Page 92] Kawasaki MULE3010 Manual 4-2 ENGINE TOP END Exploded View T1: 8.8 N·m (0.9 kgf·m, 78 in·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) T3: 22 N·m (2.2 kgf·m, 16 ft·lb) T4: 23 N·m (2.3 kgf·m, 17 ft·lb) L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide g... [Page 93] Kawasaki MULE3010 Manual ENGINE TOP END 4-3 Specifications Item Standard Service Limit Cylinder Head Cylinder Compression (Usable Range) 1 000 ∼ 1 520 kPa (10.2 ∼ 15.5 kgf/cm², 145 ∼ 220 psi) @490 r/min (rpm) ––– Cylinder Head Warp ––– 0.03 mm (0.001 in.) ... [Page 94] Kawasaki MULE3010 Manual 4-4 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Tilt up the cargo bed. • Thoroughly warm up the engine so that the engine oil be- tween the piston and the cylinder wall will help seal com- pression as it does during normal run... [Page 95] Kawasaki MULE3010 Manual ENGINE TOP END 4-5 Cylinder H ead • Remove: Choke Cable Bracket Bolt [A] Choke Cable Bracket [B] Breather Hose [C] Coolant Hose [D] • Remove: Bands [A] Intake Manifold Bolts [B] Intake Manifold [C] Muffler and Exhaust Pipe Alternator Cover [D] �... [Page 96] Kawasaki MULE3010 Manual 4-6 ENGINE TOP END Cylinder Head • Remove: Cylinder Head Bolts [A] Cylinder Head [B] Cylinder Head Gasket Rocker Arm Push Rods Cylinder Head Installation • Clean the mating surface of the cylinder head and the cylinder. • Replace the gasket wit... [Page 97] Kawasaki MULE3010 Manual ENGINE TOP END 4-7 Cylinder H ead • Tighten the cylinder head bolts in the order shown. Torque - Cylinder Head Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb) • Tighten the intake manifold bolts in the order shown. • Adjust: Valve Clearance (See Valve C... [Page 98] Kawasaki MULE3010 Manual 4-8 ENGINE TOP END Cylinder Head • Remove: Valve Spring Retainers [A] Split Keepers [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] �... [Page 99] Kawasaki MULE3010 Manual ENGINE TOP END 4-9 Valves Valve Clearance Inspection NOTE ○ Valve clearance must be checked when the engine is cold (at room temperature). • Remove: Alternator Cover [A] • Remove: Cylinder Head Covers [A] Spark Plugs • Turn the alternator rot... [Page 100] Kawasaki MULE3010 Manual 4-10 ENGINE TOP END Valves Valve Clearance Adjustment • Loosen the valve adjusting screw locknut [A]. • Turn the valve adjusting screw [B] until the correct clear- ance is obtained. • Holding the adjusting screw with the holder [C], tighten the... How To Repair Brakes On 2005 Kawasaki Mule 3010? 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