Mule 4010-4000 4x4 en Ingles

MULE 4010 4×4
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
This quick reference guide will assist

Electrical System 17 j
you in locating a desired topic or pro-
cedure.
Appendix 18 j
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
MULE 4010 4×4
MULE 4000
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)
COUNTRY AND AREA CODES

CA Canada US United States
CAL California
MULE 4010 4×4: KAF620M/N

MULE 4000: KAF620P
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 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.
that are necessary when servicing Kawasaki • Indicates

done.
a procedural step or work to be
vehicles are introduced by the Service Man-
ual. Genuine parts provided as spare parts ○Indicates a procedural sub-step or how to do
are listed in the Parts Catalog. the work of the procedural step it follows. It
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
also precedes the text of a NOTE.
Indicates a conditional step or what action to
• Remember to keep complete records of main-
tenance and repair with dates and any new
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
parts installed. lows.
In most chapters an exploded view illustration
of the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into instructions indicating which parts require spec-
its major systems and these systems make up ified tightening torque, oil, grease or a locking
the manual’s chapters. The Quick Reference agent during assembly.
GENERAL INFORMATION 1-1
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.
Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts

After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
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.
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.
Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing

the seal.
Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation

When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from right side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
Model Identification
KAF620M9 Left Side View
KAF620M9 Right Side View
Frame Number Engine Number

KAF620N9 Left Side View
KAF620N9 Right 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.
KAF620P9 Left Side View
KAF620P9 Right Side View

General Specifications
Items KAF620M9 ∼ ME/N9

Dimensions
Overall Length (KAF620M9 ∼ MC/N9) 3 005 mm (118.31 in.)
(KAF620MD ∼) 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 175 mm (6.89 in.)
Seat Height 865 mm (34.06 in.)
Curb Mass: (KAF620M9 ∼ MA, US and CA) 638 kg (1 407 lb)
(KAF620M9 ∼ MA, CAL) (KAF620MB ∼ MC) 639 kg (1 409 lb)
(KAF620MD ∼) 649 kg (1 431 lb)
(KAF620N, US) 648 kg (1 429 lb)
(KAF620N, CAL) 649 kg (1 431 lb)
Front (KAF620M9 ∼ MC/N9) 298 kg (657 lb)
(KAF620MD ∼) 306 kg (675 lb)
Rear (KAF620M9 ∼ MA, US and CA) 340 kg (750 lb)
(KAF620M9 ∼ MA, CAL) (KAF620MB ∼ MC) 341 kg (752 lb)
(KAF620MD ∼) 343 kg (756 lb)
(KAF620N, US) 350 kg (772 lb)
(KAF620N, CAL) 351 kg (774 lb)
Fuel Tank Capacity (KAF620M9 ∼ MC/N9) 23.5 L (6.2 US gal.)
(KAF620MD ∼) 24 L (6.3 US gal.)
Cargo Bed (L × W × H) (KAF620M9 ∼MC/N9)1 175 × 1 310 × 288 mm (46.26 ×
51.57 × 11.34 in.)
(KAF620MD ∼) 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
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)
Low 3.750 (51/28 × 25/20 × 28/17)
Reverse:
Low 4.220 (41/20 × 25/20 × 28/17)
Final Drive System:
Type 2-speed, automatic, reverse gear drive (4WD/2WD)
Reduction Ratio:
Front (KAF620M9 ∼ MA/N9) 5.4 (81/15)
(KAF620MB ∼) 5.200 (18/15 × 39/9)
Rear (KAF620M9 ∼ MA/N9) 5.4 (81/15)
(KAF620MB ∼) 5.429 (76/14)
Overall Drive Ratio:
Forward:
High (KAF620M9 ∼ MA/N9) 8.360
(KAF620MB ∼) 8.404
Low (KAF620M9 ∼ MA/N9) 17.212
(KAF620MB ∼) 17.303
Reverse:
Low (KAF620M9 ∼ MA/N9) 19.372
(KAF620MB ∼) 19.475
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
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)
Frame
Type Steel tube, Ladder
Caster (Rake Angle) 7.5°
Camber 0.8°
Trail 35 mm (1.4 in.)
Tire:
Front and Rear 23 × 11.00-10, Tubeless
Rim Size:
Front and Rear 10 × 8.5 AT
Steering Type Rack and pinion (Electric power steering)
Suspension:
Front:
Type MacPherson strut
Wheel Travel 100 mm (3.9 in.)
Rear:
Type De Dion axle
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.
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
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
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
Frame
Type Steel tube, Ladder
Caster (Rake Angle) 7.5°
Camber 0.8°
Trail 35 mm (1.4 in.)
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
Rear:
Type De Dion axle
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.
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 Volume: Units of Pressure:

L × 0.2642 = gal (US) kPa × 0.01020 = kgf/cm²
L × 0.2200 = gal (IMP) kPa × 0.1450 = psi
L × 1.057 = qt (US) kPa × 0.7501 = cmHg
L × 0.8799 = qt (IMP) kgf/cm² × 98.07 = kPa
L × 2.113 = pint (US) kgf/cm² × 14.22 = psi
L × 1.816 = pint (IMP) cmHg × 1.333 = kPa
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (IMP) Units of Speed:
mL × 0.06102 = cu in. km/h × 0.6214 = mph
Units of Force: Units of Power:

N × 0.1020 = kg kW × 1.360 = PS
N × 0.2248 = lb kW × 1.341 = HP
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
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
Fuel hoses - replace 5 years 2-15

Evaporative emission control system -
inspect (CAL Model and KAF620MB ∼/PB
∼)
• • 2-18
Coolant - change 2 years 2-19

Radiator - clean* • • 2-22
Water hoses and connections - inspect 1 year • • 2-22
Valve clearance - inspect • • 2-23
Spark arrester - clean • 2-25
Converter air cleaner element - clean* • • 2-25
Converter dust or water - drain* • 2-26
Converter drive belt - inspect* • 2-26
Converter drive belt deflection- inspect* • 2-26
Converter driven pulley shoe - inspect* • 2-27
Engine oil - change* 1 year • • 2-28
Oil filter - replace* • • 2-29
Transmission oil - change* 1 year • • 2-30
•*:: Clean, adjust, lubricate, torque, or replace parts as necessary.

Service more frequently when operated in mud, dust, or other harsh riding conditions.
Periodic Maintenance Chart
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
Seat belt - inspect • 2-43

Spark plug - clean and gap inspect • 2-43
Brake light switch - inspect • • 2-44
General lubrication - perform* • 2-44
Bolts, nuts, and fasteners tightness -
inspect • • 2-45
•*:: Service
Clean, adjust, lubricate, torque, or replace parts as necessary.
more frequently when operated in mud, dust, or other harsh riding conditions.
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of
a non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:

B: Apply brake fluid.
EO: Apply an oil to the threads, seated surface, or washer.
L: Apply a non-permanent locking agent to the threads.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide
grease in a weight ratio 10:1).
R: Replacement Part
S: Tighten the fasteners following the specified sequence.
SS: Apply a silicone sealant to the threads.
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
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
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
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
Hi/Low Gear Case Bolts 20 2.0 15
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)
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
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
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
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
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
Basic Torque for General Fasteners of Frame Parts

Threads dia. Torque
mm (in.) N·m kgf·m ft·lb
5 (0.20) 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 (0.24) 5.8 ∼ 7.9 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 (0.31) 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 14
10 (0.39) 26 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
12 (0.47) 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
Specifications
Item Standard Service Limit

Fuel System
Throttle Pedal Free Play 5 ∼ 10 mm (0.2 ∼ 0.4 in.) – – –
Idle Speed 900 ∼ 1 000 r/min (rpm) – – –
Cooling System
Coolant:
Type Permanent type of antifreeze (Soft water and – – –
ethylene glycol plus corrosion and rust inhibitor
chemicals for aluminum engine and radiators)
Color Green – – –
Mixed Ratio Soft water 50%, coolant 50% – – –
Freezing Point –35°C (–31°F) – – –
Total Amount 4.3 L (4.5 US qt) – – –
Engine Top End
Valve Clearance (When Cold) 0.25 mm (0.0098 in.) – – –
Converter System
Belt Width 30.3 mm (1.19 in.) 28.8 mm (1.13 in.)
Belt Deflection 28 ∼ 33 mm (1.1 ∼ 1.3 in.) 45 mm (1.8 in.)
Wear Shoe Width ––– 16.3 mm (0.64 in.)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, – – –
MA1 or MA2 – – –
Viscosity SAE 10W-40 – – –
Capacity 1.3 L (1.4 US qt) (when filter is not removed) – – –
1.5 L (1.6 US qt) (when filter is removed) – – –
1.8 L (1.9 US qt) (when engine is completely – – –
dry)
Oil Level Between F and L marks on dipstick – – –
Transmission
Transmission Oil:
Type API "GL-6" Hypoid gear oil – – –
Viscosity SAE90: above 5°C (41°F) – – –
SAE80: below 5°C (41°F) – – –
Capacity (KAF620M/N) 2.5 L (2.6 US qt) – – –
(KAF620P) 2.2 L (2.3 US qt) – – –
Oil Level Between H and L lines on dipstick – – –
Wheels/Tires
Tire Tread Depth 13.2 mm (0.52 in.) 3 mm (0.12 in.)
Final Drive
(KAF620M/N)
Front Final Gear Case Oil: – – –
Type API "GL-5 or GL-6" hypoid gear oil for LSD
(Limited Slip Differential gears)
Viscosity SAE90 or SAE140 – – –
Capacity 0.4 L (0.4 US qt) – – –
Oil Level Filler opening level – – –
Specifications

Brakes
Brake Fluid:
Type DOT3 – – –
Fluid Level Between upper and lower level lines – – –
Brake Pedal Play 2 ∼ 10 mm (0.08 ∼ 0.39 in.) – – –
Brake Drum Inside Diameter 180.000 ∼ 180.160 mm 180.75 mm
(7.0866 ∼ 7.0929 in.) (7.116 in.)
Brake Shoe Lining Thickness 4.5 mm (0.18 in.) 1.0 mm (0.04 in.)
Parking Brake Lever Travel 8 ∼ 12 notches (clicks) at 200 N (20 kgf, 44 lb) – – –
Steering
Steering Wheel Free Play 0 ∼ 20 mm (0 ∼ 0.79 in.) – – –
Electrical System
Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) – – –
Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel – – –
Special Tools
Inside Circlip Pliers: Oil Filter Wrench:
57001-143 57001-1249
Valve Adjusting Screw Holder:

57001-1217
Periodic Maintenance Procedures
Fuel System
Throttle Pedal Free Play Inspection
• Check that the throttle pedal moves smoothly from full
open to close.
If the throttle pedal does not return properly, lubricate the
throttle cable.
• Check the throttle pedal free play [A].
If the free play is incorrect, adjust the throttle cable.
Throttle Pedal Free Play
Standard: 5 ∼ 10 mm (0.2 ∼ 0.4 in.)
Throttle Pedal Free Play Adjustment

• Tilt up the cargo bed.
• Loosen
end.
the adjuster mounting nuts [A] at the cable lower
• Slide the adjuster [B] until the proper amount of throttle

pedal free play is obtained.
• Tighten the mounting nuts securely.
• With the transmission
Start the engine.
• a few times to make insure
neutral, operate the throttle pedal
that the idle speed does not
change.
If the idle speed does change, the throttle cable may be
improperly adjusted, incorrectly routed, or it may be dam-
aged.
• Correct any of these conditions before operation.
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.
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].
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.
Idle Speed Inspection

• Start the engine and warm it up thoroughly.
• Check the idle speed with a precise tachometer.
Idle Speed
Standard: 900 ∼ 1 000 r/min (rpm)
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.

• detaches thethrottle
Loosen the lever stopper screw [B] until the screw
throttle lever [C].
• contacts the throttlelever
Tighten the throttle stopper screw until the screw
lever, and then tighten the screw
about one half rotation (180°).
• Tighten the locknut.
If the idle speed is out of the specified range, check the

following items.
Main Throttle Sensor Position (see Main Throttle Sensor
Installation in the Fuel System (DFI) chapter)
Stop Screw Position (see Stop Screw Replacement in
the Fuel System (DFI) chapter)
Subthrottle Sensor Position (see Subthrottle Sensor In-
stallation in the Fuel System (DFI) chapter)
Subthrottle Valve Mechanism (see Subthrottle Valve
Mechanism Inspection in the Fuel System (DFI) chap-
ter)
Air Cleaner Element Cleaning
• Unlock the clamps [A].
• Air Cleaner Cover [B]
Remove:
• 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.
•○Install the cover [A] and lock the clamps.

Face the TOP mark [B] upward.
• Reset the Air Filter Restriction Gauge [A] (push [B] its
reset button).
Air Cleaner Housing Dust or Water Draining

• Push open the drain tube [A] on the bottom of the air
cleaner housing.
Fuel Hoses or Pipe and Connections Inspection

• Lift up the cargo bed and seat.
• Check the fuel hoses and fittings for deterioration, cracks
and signs of leakage.
Replace the fuel hose if any fraying, leak [A], cracks [B]
or bulges [C] are noticed.
• Check that the hoses are securely connected and clamps
are installed correctly.
• When installing, route the hoses according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
• When installing the fuel hoses and pipe, avoid sharp
bending, kinking, flattening or twisting, and route the fuel
hoses with a minimum of bending so that the fuel flow
will not be obstructed.
Replace the hose if it has been sharply bent or kinked.
Fuel Hoses Replacement
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 flame
or sparks; this includes any appliance with a pilot
light.
• Tilt up the seat and cargo bed.

• Wipe offtotheplace
Be sure a piece of cloth around the fuel hose joint.
• using a clothdirt of the surface [A] around the connection
or a soft brush.
When removing with standard tip screwdriver

•Insert the standard tip screwdriver [A] into the slit on the
joint lock [B].
•Turn the driver to disconnect the joint lock.
When removing with fingers
•Open and push up [C] the joint lock with your fingers.
NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.
• 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.
• Clean the pipe [A].

• [C] to keep
Cover the pipe and the hose joint [B] with the vinyl bags
it clean.
• Remove the vinyl bag on the pipe.

• foreign materials
Check that there are no flaws, burns, and adhesion of
on the delivery pipe [A].
• Replace the fuel hose with a new one.
• Repeat the previous step to remove the other side of the

fuel hose.
• Remove the fuel hose from the clamps.
• Run the fuel fuel
Replace the hose with a new one.
• Routing section in the
hose correctly (see Cable, Wire, and Hose
Appendix chapter).
• 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.
• 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].
Evaporative Emission Control System Inspection

(CAL Model and KAF620MB ∼/PB ∼)
•○Inspect the canister as follows.
Tilt up the seat.
○Remove the canister [A], and disconnect the hoses from
the canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○The canister is designed to work well through the utility
vehicle’s life without any maintenance if it is used under
normal conditions.
• Check the hoses of the evaporative emission control sys-

tem as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter. Refer to the diagram
of the evaporative emission control system in the Fuel
System chapter too.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and run the hoses with a minimum of
bending so that the emission flow will not be obstructed.
Cooling System
Coolant Change
Coolant Draining
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
• 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.
• Place a container under the drain plugs.

• Front Final Gear Case Skid Plate
Remove:
Coolant Drain Plugs [A] at Water Pipes

• 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.
• Place a container under the drain plug.

• Coolant Drain Plug [A] at Front Cylinder
Remove:
• Place a container under the drain plug.

• Torque Converter Case
Remove:
Coolant Drain Plug [A] at Rear Cylinder

Coolant Filling
•Tighten the drain plugs.
Torque - Coolant Drain Plugs (Cylinder): 17 N·m (1.7 kgf·m,
13 ft·lb)
• Remove:
Radiator Cap
Air Bleeder Bolts [A]
• Pour the coolant slowly so that the air in the engine and
radiator can escape.
NOTE
○Pour in the coolant slowly so that the air in the engine
and radiator can escape.
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.
Water and Coolant Mixture Ratio (Recommended)

Soft Water : 50%
Coolant : 50%
Freezing Point : –35°C (–31°F)
Total Amount : 4.3 L (4.5 US qt)
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.
• Install the reserve tank cap.

Radiator Cleaning
NOTICE
Clean the radiator screen and the radiator in ac-
cordance with the Periodic Maintenance Chart.
In dusty areas, they should be cleaned more fre-
quently than the recommended interval. After
riding through muddy terrains, the radiator screen
and the radiator should be cleaned immediately.
• 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.
Water Hose and Connection Inspection

○The high pressure inside the water hose can cause
coolant to leak or the hose to burst if the line is not prop-
erly maintained. Visually inspect the hoses [A] for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks or bulges are no-
ticed.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked when the engine is
cold (at room temperature).
• 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]
• Turn the alternator rotor clockwise so that the mark "1"

[A] or "2" [B] on the rotor aligns with the mark [C] on the
crankcase breather cover. Check both rocker arms are
free. If not, turn the rotor more one turn and free both
rocker arms.
NOTE
○The mark "1" is for the No. 1 cylinder, and "2" is for the
No. 2 cylinder.
• Using a thickness gauge [A], measure the valve clearance

between the rocker arm and the valve stem.
If the valve clearance is incorrect, adjust it.
Valve Clearance (when cold)
Standard: 0.25 mm (0.0098 in.)
Valve Clearance Adjustment

• Loosen the valve adjusting screw locknut [A].
• ance is obtained.
Turn the valve adjusting screw [B] until the correct clear-
• Holding the adjusting screw with the holder [C], tighten

the locknut.
Special Tool - Valve Adjusting Screw Holder: 57001-1217
Torque - Valve Adjusting Screw Locknut: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Spark Arrester Cleaning
WARNING
The muffler can become extremely hot during nor-
mal operation and cause severe burns. Since the
engine must be running during this procedure, wear
heat-resistant gloves while cleaning the spark ar-
rester.
• Remove the drain plug [A] from the muffler [B].

• In an openparking
Apply the brake.
• the engine with
area away from combustible materials, start
the gear shift lever in the N (neutral) po-
sition.
• Raise and lower engine speed while tapping on the muf-
fler with a rubber mallet until the carbon particles are
purged from the muffler.
DANGER
Exhaust gas contains carbon monoxide, a color-
less, odorless poisonous gas. Inhaling carbon
monoxide can cause serious brain injury or death.
DO NOT run the engine in enclosed areas. Operate
only in a well-ventilated area.
• Stop the engine.

• Install the drain plug.
Converter System
Converter Air Cleaner Element Cleaning/Inspec-
tion
NOTE
○In dusty areas, the element should be cleaned more
frequently than the recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
WARNING
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.
• Remove the air cleaner element, and separate the foam

element [A] from the paper element [B].
• Clean the foam element in a bath of a high flash-point
solvent, and then dry it with compressed air or by shaking
it.
NOTICE
Do not use compressed air to clean the paper ele-
ment.
Do not oil the paper element.
Converter Dust or Water Draining
• Unscrew the clamp screw [A] and remove the drain hose
[B] on the bottom of the converter housing to expel dust
and/or water accumulated inside.
Converter Drive Belt Inspection

• Measure the width [A] of the belt.
If any measurements exceed the service limit, replace the
belt.
Belt Width
Service Limit: 28.8 mm (1.13 in.)
• Check the belt for wear, cracks, breaks or peeling.

If necessary, replace the belt with a new one.
Belt [A]
Crack [B]
Broken [C]
NOTE
○Whenever the belt is replaced, inspect the drive and the
driven pulleys.
Drive Belt Deflection Inspection

• Remove the torque converter cover (see Torque Con-
verter Cover Removal in the Converter System chapter).
• Put the transmission in neutral and rotate the driven pulley
by hand to make sure the belt is shifted all the way to the
top of the driven pulley.
•Measure the belt deflection as shown:
○Place a straightedge [A] on top of the belt between the
drive pulley [B] and the driven pulley [C].
○Use a ruler to push the belt away from the straightedge.
Push hard, but with no more force than 59 N (6 kg, 13 lb).
Belt Deflection
Standard: 28 ∼ 33 mm (1.1 ∼ 1.3 in.)
Service Limit: 45 mm (1.8 in.)
If the belt deflection is not within the specified range, first
measure the drive belt width (see Converter Drive Belt
Inspection). Adjust the deflection by adding or removing
spacers between the fixed sheave and movable sheave
in the driven pulley.
• When adjusting the deflection, less is better than more.
Less deflection will maintain better performance for more
time as the belt width decreases by normal wear, which
causes the deflection to increase with usage.
Drive Belt Deflection Adjustment
• Disassemble the driven pulley (see Driven Pulley Disas-
sembly in the Converter System chapter).
If the belt deflection is more than 45 mm (1.8 in.), remove
the spacer of 1.0 mm (0.039 in.).
○Do not remove the all spacers. Remain any one of spac-
ers to prevent the contact of both sheaves.
○The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer
thickness equals about 1.3 mm (0.051 in.) change in belt
deflection.
If the belt deflection is less than 28 mm (1.1 in.), add the
spacers [A] to increase it.
○The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer
thickness equals about 1.6 mm (0.063 in.) change in belt
deflection.
Spacers
Part No. Thickness
92026-1603 1.0 mm (0.039 in.)
92026-1507 0.5 mm (0.020 in.)
92026-1508 0.6 mm (0.024 in.)
92026-1510 0.8 mm (0.031 in.)
• Assemble the driven pulley (see Driven Pulley Assembly

in the Converter System chapter).
• With the transmission in neutral, rotate the driven pulley
to allow the belt to return to the top of the sheaves before
measuring the belt deflection.
• Measure the belt deflection again and repeat the above
procedures until it is within the standard range.
Even if the deflection is adjusted, when the belt deflection
is greater than the service limit, replace the drive belt.
• Using a suitable holder, apply a non-permanent locking
agent to the driven pulley bolt and tighten it.
Torque - Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
Converter Driven Pulley Shoe Inspection

• Remove the driven pulley (see Drive and Driven Pulley
Removal in the Converter System chapter).
• Disassembly the driven pulley.
If the ramps [A] or the wear shoes [B] are damaged or
worn, replace the ramp or the shoes.
If the wear shoe contact area width [A] is greater than the
service limit, replace the shoe [B].
Wear Shoe Width
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
If the oil filter is to be changed, replace it with a new one.

• Check the gasket at the drain plug for damage.
Replace the gasket with a new one if it is damaged.
• After the oil has completely drained out, install the drain
plug with the gasket.
Torque - Engine Oil Drain Plug: 32 N·m (3.3 kgf·m, 24 ft·lb)
• Fill the engine with a good quality engine oil as specified
in the table.
• Check the oil level.
Engine Oil
Type: API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity: SAE 10W-40
Capacity: 1.3 L (1.4 US qt) (when filter is not removed)
1.5 L (1.6 US qt) (when filter is removed)
1.8 L (1.9 US qt) (when engine is completely
dry)
Oil level: Between F and L lines on dipstick
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.
Oil Filter Removal
•○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
Oil Filter Installation

• Apply engine oil:
Oil Filter Gasket
•○Tightenthethenew
Install filter.
filter with the oil filter wrench.
Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 17.6 N·m (1.8 kgf·m, 13 ft·lb)
• Add the engine oil (see Engine Oil Change).
• age and thewarm
Thoroughly up the engine, and check the oil leak-
oil level.
If necessary, add more engine oil.
Transmission
Transmission Oil Change
• Warm up the oil by running the vehicle so that the oil will
pick up any sediment and drain easily. Then stop the
vehicle.
• Place an oil pan beneath the transmission case.
• Remove the transmission oil drain plug [A], and let the oil
drain completely.
• Check the gasket at the drain plug for damage.
Replace the gasket with a new one if it is damaged.
plug with the gasket.
Torque - Transmission Oil Drain Plug: 15 N·m (1.5 kgf·m,
11 ft·lb)
• Fill the transmission case with a good quality oil as spec-
ified in the table.
• Check the oil level.
Transmission Oil
Type: API "GL-6" Hypoid gear oil
Viscosity: SAE 90: above 5°C (41°F)
Capacity: (KAF620M/N) 2.5 L (2.6 US qt)
(KAF620P) 2.2 L (2.3 US qt)
Oil Level: Between H and L lines on dipstick
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.
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 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.
plug with a new aluminum gasket, and tighten it.
Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
• 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.
• Raise the front cargo hood.

• Remove:
Rubber Cap [A]
• 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.
Brake Fluid Change

• Tilt up the front cargo hood.
• Remove the rubber cap.
• Check that there is plenty of fluid in the reservoir [A].

NOTE
○The fluid level must be checked several times during
the fluid changing and replenished as necessary. If the
fluid in the reservoir runs completely out any time during
fluid changing, air bleeding must be done since air will
have entered the line.
• Remove the wheel for extra clearance (see Wheel Re-

moval in the Wheels/Tires chapter).
• Remove the reservoir cap.
• cylinder. rubber cap from the bleed valve on the wheel
Remove the
• 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.
• Open the bleed valve, apply pressure to the brake pedal,

close the valve while the brake is applied, and then quickly
release the pedal. Repeat this operation until fresh brake
fluid comes out from the plastic hose or the color of the
fluid changes.
1. Open bleed valve.
2. Apply brake pedal and hold it.
3. Close bleed valve.
4. Release brake pedal.
• Tighten:
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Repeat the previous step for each wheel.
• When brake fluid changing is finished, add the fluid to the
upper level in the reservoir.
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
If necessary, bleed the air from the brake lines (see Brake
Line Air Bleeding in the Brakes chapter).
WARNING
Air in the brake lines diminish braking 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.
• Install the removed parts.

Brake Pedal Free Play Inspection
• Check brake pedal free play [A].
Brake Pedal Free Play
Standard: 2 ∼ 10 mm (0.08 ∼ 0.39 in.)
If the free play is not correct, adjust it.
• 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.
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]
○Be careful of the secondary cup [A] direction [B].
• Before assembly, clean all parts including the master

cylinder with brake fluid or alcohol, and apply brake fluid
to the removed parts and the inner wall of the cylinder.
NOTICE
Use only brake fluid, isopropyl alcohol, or ethyl al-
cohol, for cleaning brake parts. Do not use any
other fluid for cleaning these parts. Gasoline, 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.
• Push the pistons in all the way with a screwdriver and

install the piston stop bolt. Use a new aluminum washer.
• Tighten:
Torque - Piston Stop Bolt: 8.9 N·m (0.91 kgf·m, 79 in·lb)
Reservoir Clamp Bolt: 6.2 N·m (0.63 kgf·m, 55
in·lb)
Brake Hose and Pipe Inspection
• The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace it if any cracks [B] or bulges [C] are noticed.
• The metal pipe will rust if the plating is damaged.
Replace the pipe if it is rusted, cracked (especially check
the fittings), or if the plating is badly scratched.
Brake Hose and Pipe Replacement
• To remove the metal pipes [A], unscrew the nipples [B].
• To remove the hoses [C], remove the banjo bolts [D]
and/or pull out the retainers [E] (see below).
• Immediately wipe up any brake fluid that spills.
NOTICE
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
• Use a new aluminum washer for each side of the hose

fittings at the master cylinder.
• Apply brake fluid:
Brake Pipe Nipple Threads
• Tighten:
Torque - Brake Hose Banjo Bolts: 24.5 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Nipples: 17.7 N·m (1.8 kgf·m, 13 ft·lb)
• Check that the brake line has proper fluid pressure and
no fluid leakage.
[A] Metal Pipes
[B] Nipples
[C] Hoses
[E] Retainers
Brake Wear Inspection

• Remove the brake drum (see Brake Drum Removal in the
Brakes chapter).
• Measure
points.
the inside diameter [A] of the drum at several
If any measurement is greater than the service limit, re-

place the drum.
If the drum is worn unevenly or scored, lightly turn the
drum on a brake drum lathe or replace it. Do not turn the
drum beyond the service limit.
Brake Drum Inside Diameter
Standard: 180.000 ∼ 180.160 mm (7.0866 ∼ 7.0929
in.)
• Measure the lining thickness at several points.

Brake Shoe Lining Thickness
If any measurement is less than the service limit, replace
both shoes as a set.
If the lining thickness is greater than the service limit, do
the following before installing the shoes.
• File or sand down any high spots on the surface on the
lining.
• Use a wire brush to remove any foreign particles from the
lining.
• Wash off any oil or grease with an oilless solvent.
NOTICE
Do not use a solvent which will leave on oily residue
or the shoes will have to be replaced.
Brake Wheel Cylinder Assembly Replacement
• Remove:
Brake Drum (see Brake Drum Removal in the Brakes
chapter)
Brake Pipe Nipple [A]
○Immediately wipe up any brake fluid that spills.
NOTICE
diately.
Loosen the brake wheel cylinder mounting bolts [B] for
cylinder removal.
• 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.
• Remove the collar [E] on the rear brake panel.
• Replace the rear wheel cylinder with a new one.

• can be reinstalled
Set the brake shoe clearance adjuster so that the drum
on the panel assembly.
(Front Brake Panel)
○Turn one of the wheel cylinder ends [A] while pushing it
in. Keep the other end [B] from turning until both the ends
of the pistons are back in the cylinder completely.
(Rear Brake Panel)
○Pry the ratchet lever [A] with a screwdriver [B] to reset the
shoe clearance adjuster in its original position [C]
• Apply lithium grease (NLGI Grade No.2):

Brake Panel Seating Surface
• Apply a non-permanent locking agent:
Brake Panel Mounting Bolts
• Tighten:
Torque - Wheel Cylinder Mounting Bolts: 10.3 N·m (1.1
kgf·m, 91 in·lb)
Wheel Cylinder Mounting Nuts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
Brake Panel Mounting Bolts: 44.1 N·m (4.5 kgf·m,
33 ft·lb)
Brake Pipe Nipple: 17.7 N·m (1.8 kgf·m, 13 ft·lb)
• Grease [A]:
Brake Panel and Brake Shoe Contact Points
Wheel Cylinder Piston Ends
Brake Shoe Anchor Ends
• Grease (rear brake only) [B]:
Shoe Clearance Adjuster Pivots
Shoe Clearance Adjuster and Shoe Contact Points
Parking Brake Lever Travel Inspection
•○Check parking brake lever travel [A].
Pull the parking brake lever [B] upward slowly all way.
Count the number of notches (clicks) during lever travel.
If the lever travel is not correct, adjust it.
Parking Brake Lever Travel
Standard: 8 ∼ 12 notches (clicks) at 200 N (20 kgf,
44 lb)
• Release
position.
the parking brake and return the lever to its rest
• 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].
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.
Frame
Seat Belt Inspection
• Check the belt [A] for damage or tear.
If necessary, replace the belt with a new one.
• Check the tightness torque of the seat belt mounting bolts

(both sides).
• Tighten:
Torque - Seat Belt Mounting Bolt [A]: 34.3 N·m 3.5 kgf·m,
25 ft·lb)
Seat Belt Buckle Mounting Bolts [B]: 34.3 N·m 3.5
kgf·m, 25 ft·lb)
•○Check the operation of the buckle [A].

Set the plate [B] in the buckle, and confirm the plate does
not come off when pulling it.
○Set the plate in the buckle, and confirm the plate comes
off when the buckle button [C] is pushed
If operation is not correct, visually inspect the plate.
If the plate is damaged, replace the plate assembly with
a new one.
If the plate is not damaged, replace the buckle assembly.
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.)
Brake Light Switch Inspection
• Check the operation of the brake light switch by depress-
ing the brake pedal. The brake light should go on after 10
mm (0.4 in.) of pedal travel [A].
If it does not, adjust the brake light switch [A] up or down.

To change the switch position, turn the adjusting nut [B].
Brake Light Switch Timing
Standard: ON after 10 mm (0.39 in.) of pedal travel
NOTICE
To avoid damaging the electrical connections in-
side the switch, be sure that the switch body does
not turn during adjustment.
General Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure spray water, perform the general lubri-
cation.
Pivots and Points: Lubricate with Grease.

Seat Brackets
Cargo Bed Mounting Pins
Throttle Pedal Pivot
Throttle Cable Ends
Choke Cable End
Brake Pedal Pivot
Parking Brake Cables End
Transmission Shift Control Lever Pivot
Differential Shift Cable Upper End
2WD/4WD Shift Lever Pivot
Propeller Shaft Bearing [A] (under seat)
○Grease the propeller shaft bearing using the grease nip-
ple [B].
Cables: Lubricate with Cable Lubrication.
Throttle Cable
Differential Shift Cable
2WD/4WD Shift Cable (KAF620M/N)
•Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a pressure cable
lubricator with an aerosol cable lubricant.
Cables: Lubricate with Motor Oil.
Parking Brake Cables
• With the cable disconnect at both ends, the cable should

move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Bolts, Nuts, and Fasteners

Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
○Check the engine fastener tightness when the engine is
cold (at room temperature).
If there are loose fasteners, first loosen by 1/2 turn, then
retorque them to the specified torque following the speci-
fied tightening sequence. Refer to the appropriate chap-
ter for torque specifications. If torque specifications are
not in the appropriate chapter, see the basic torque table
(see Torque and Locking Agent in this chapter).
If cotter pins are damaged, replace them with new ones.
Nut, Bolt, and Fasteners to be checked

Engine:
Engine Mounting Bolts
Exhaust Pipe Holder Nuts
Exhaust Pipe and Muffler Clamp Bolt
Muffler Mounting Bolts
Throttle Pedal Pivot Clip
Fuel Tank Mounting Bolts
Transmission/Final Drive:
Axle Nuts and Cotter Pins
Drive Shaft Bracket Mounting Nuts
Transmission Shift Cable Upper End Clip
Transmission Shift Shaft Lever Clamp Bolt
Differential Shift Lever Pivot Clip
Differential Shift Cable Upper End Clip
Differential Shift Shaft Lever Mounting Nut
Propeller Shaft Bearing Mounting Nuts
2WD/4WD Shift Lever Pivot Clip (KAF620M/N)
2WD/4WD Shift Shaft Lever Mounting Nut (KAF620M/N)
Hi/Low Shift Shaft Lever Clamp Bolt
Hi/Low Shift Cable Upper End Clip
Hi/Low Shift Lever Mounting Nut
Wheels:
Wheel Nuts
Brakes:
Master Cylinder Mounting Bolts
Master Cylinder Push Rod Clevis Pin Clip
Parking Brake Lever Assembly Mounting Bolts
Parking Brake Cable Lower End Clevis Pin Cotter Pins
Brake Pedal Pivot Shaft Cotter Pin
Suspension:
Suspension Arm Pivot Bolts
Strut Mounting Nuts
Strut Clamp Nuts and Cotter Pins
Leaf Spring Mounting Nuts
Shock Absorber Mounting Nuts
Steering:
Steering Wheel Mounting Nut
Intermediate Shaft Clamp Bolts (KAF620P)
Tie-rod End Nuts and Cotter Pins
Tie-rod End Locknuts
Suspension Arm Joint Nuts and Cotter Pins
Steering Shaft Mounting Bolts and Nuts
Universal Joint Clamp Bolts (KAF620M/N)
Frame:
Front and Rear Bar Mounting Bolts and Nuts
Front Guard Mounting Nuts
Cargo Bed Hook Mounting Bolts
Cargo Bed Mounting Pin Clips
Screen Mounting Nuts
Seat Bracket Nuts
Seat Back Mounting Nuts
Seat Belt Mounting Bolts
Battery Holder Nut
Skid Plate Mounting Bolts
Rear End Sub-frame Mounting Nuts
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)

Table of Contents
Exploded View........................................................................................................................ 3-4
Exploded View (KAF620M9 ∼ MC/N9/P9 ∼ PC)..................................................................... 3-8
Exploded View (KAF620MD ∼/PD ∼)...................................................................................... 3-10
Specifications ......................................................................................................................... 3-12 3
Special Tools and Sealant ...................................................................................................... 3-14
DFI System............................................................................................................................. 3-15
DFI Parts Location.................................................................................................................. 3-19
DFI Servicing Precautions ...................................................................................................... 3-22
DFI Servicing Precautions ................................................................................................... 3-22
Troubleshooting the DFI System ............................................................................................ 3-24
Outline ................................................................................................................................. 3-24
Inquiries to Rider.................................................................................................................. 3-27
DFI System Troubleshooting Guide ....................................................................................... 3-30
Self-Diagnosis ........................................................................................................................ 3-35
Self-diagnosis Outline.......................................................................................................... 3-35
Self-diagnosis Procedures................................................................................................... 3-35
Service Code Reading ...................................................................................................... 3-37
Service Code Erasing ....................................................................................................... 3-38
Backups ............................................................................................................................... 3-39
Main Throttle Sensor, Subthrottle Sensor and Subthrottle Valve Actuator (Service Code 11) 3-40
Troubleshooting Guide of Service Code 11 ...................................................................... 3-40
Main Throttle Sensor Removal ......................................................................................... 3-40
Main Throttle Sensor Installation ...................................................................................... 3-40
Main Throttle Sensor Input Voltage Inspection ................................................................. 3-42
Main Throttle Sensor Output Voltage Inspection .............................................................. 3-44
Main Throttle Sensor Resistance Inspection .................................................................... 3-45
Subthrottle Sensor Removal ............................................................................................. 3-45
Subthrottle Sensor Installation .......................................................................................... 3-46
Subthrottle Sensor Input Voltage Inspection..................................................................... 3-48
Subthrottle Sensor Output Voltage Inspection .................................................................. 3-49
Subthrottle Sensor Resistance Inspection ........................................................................ 3-52
Subthrottle Valve Actuator Removal ................................................................................. 3-52
Subthrottle Valve Actuator Resistance Inspection ............................................................ 3-52
Subthrottle Valve Mechanism Inspection .......................................................................... 3-53
Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-55
Inlet Air Pressure Sensor Removal................................................................................... 3-55
Inlet Air Pressure Sensor Installation................................................................................ 3-55
Inlet Air Pressure Sensor Input Voltage Inspection........................................................... 3-55
Inlet Air Pressure Sensor Output Voltage Inspection........................................................ 3-56
Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-58
Inlet Air Temperature Sensor Removal ............................................................................. 3-58
Inlet Air Temperature Sensor Installation .......................................................................... 3-58
Inlet Air Temperature Sensor Output Voltage Inspection .................................................. 3-58
Inlet Air Temperature Sensor Resistance Inspection ........................................................ 3-59
Water Temperature Sensor (Service Code 14) ...................................................................... 3-60
Water Temperature Sensor Removal................................................................................ 3-60
Water Temperature Sensor Installation............................................................................. 3-60
Water Temperature Sensor Output Voltage Inspection..................................................... 3-60
Water Temperature Sensor Resistance Inspection........................................................... 3-61
Speed Sensor (Service Code 24)........................................................................................... 3-62
3-2 FUEL SYSTEM (DFI)
Speed Sensor Removal .................................................................................................... 3-62

Speed Sensor Installation ................................................................................................. 3-62
Speed Sensor Input Voltage Inspection............................................................................ 3-62
Speed Sensor Output Voltage Inspection ......................................................................... 3-63
Ignition Coils #1, #2 (Service Code 51, 52) ............................................................................ 3-65
Ignition Coil Removal/Installation...................................................................................... 3-65
Ignition Coil Primary Winding Resistance Inspection........................................................ 3-65
Ignition Coil Input Voltage Inspection................................................................................ 3-65
DFI Warning Indicator Light ................................................................................................... 3-67
DFI Warning Indicator Light Inspection ............................................................................. 3-67
DFI Warning Indicator Light Input Voltage Inspection ....................................................... 3-67
ECU ........................................................................................................................................ 3-69
ECU Removal ................................................................................................................... 3-69
ECU Installation ................................................................................................................ 3-69
ECU Power Supply Inspection.......................................................................................... 3-69
DFI Power Source .................................................................................................................. 3-72
ECU Relay Fuse Removal ................................................................................................ 3-72
ECU Relay Fuse Installation ............................................................................................. 3-72
ECU Relay Fuse Inspection.............................................................................................. 3-72
ECU Relay Removal ......................................................................................................... 3-72
ECU Relay Inspection....................................................................................................... 3-72
Fuel Line................................................................................................................................. 3-73
Fuel Pressure Inspection .................................................................................................. 3-73
Fuel Flow Rate Inspection ................................................................................................ 3-74
Fuel Pump .............................................................................................................................. 3-76
Fuel Pump Removal ......................................................................................................... 3-76
Fuel Pump Installation ...................................................................................................... 3-77
Fuel Pump Operation Inspection ...................................................................................... 3-77
Fuel Pump Operating Voltage Inspection ......................................................................... 3-78
Pressure Regulator Removal............................................................................................ 3-79
Fuel Filter Cleaning (KAF620M9 ∼ MC/N9/P9 ∼ PC)........................................................ 3-79
Fuel Filter Cleaning (KAF620MD ∼/PD ∼)......................................................................... 3-79
Fuel Pump Relay Removal ............................................................................................... 3-80
Fuel Pump Relay Inspection ............................................................................................. 3-80
Fuel Injectors .......................................................................................................................... 3-83
Fuel Injector Removal ....................................................................................................... 3-83
Fuel Injector Installation .................................................................................................... 3-83
Fuel Injector Audible Inspection........................................................................................ 3-84
Fuel Injector Resistance Inspection .................................................................................. 3-84
Fuel Injector Power Source Voltage Inspection ................................................................ 3-85
Fuel Injector Output Voltage Inspection ............................................................................ 3-86
Throttle Pedal and Cable........................................................................................................ 3-88
Throttle Pedal Free Play Inspection.................................................................................. 3-88
Throttle Pedal Free Play Adjustment ................................................................................ 3-88
Full Throttle Pedal Position Adjustment ............................................................................ 3-88
Throttle Cable Installation ................................................................................................. 3-88
Throttle Cable Lubrication and Inspection ........................................................................ 3-88
Control Panel ......................................................................................................................... 3-89
Control Panel Removal ..................................................................................................... 3-89
Control Panel Installation .................................................................................................. 3-89
Control Panel Disassembly............................................................................................... 3-89
Control Panel Assembly.................................................................................................... 3-90
Throttle Body Assy ................................................................................................................. 3-91
Idle Speed Inspection/Adjustment .................................................................................... 3-91
Throttle Body Assy Removal............................................................................................. 3-91
Throttle Body Assy Installation.......................................................................................... 3-92
Stop Screw Replacement ................................................................................................. 3-93
Inlet Manifold ......................................................................................................................... 3-96

Inlet Manifold Removal ..................................................................................................... 3-96
Inlet Manifold Installation .................................................................................................. 3-96
Air Cleaner.............................................................................................................................. 3-97
Air Cleaner Element Cleaning........................................................................................... 3-97
Air Cleaner Housing Removal........................................................................................... 3-97
Air Cleaner Housing Installation........................................................................................ 3-97
Air Cleaner Housing Dust and/or Water Inspection .......................................................... 3-97
Fuel Tank ................................................................................................................................ 3-98
Fuel Tank Removal ........................................................................................................... 3-98
Fuel Tank Installation ........................................................................................................ 3-99
Fuel Tank Cleaning/Inspection.......................................................................................... 3-100
Fuel Level Gauge Removal (KAF620M9 ∼ MC/N9/P9 ∼ PC) ........................................... 3-100
Fuel Level Gauge Installation (KAF620M9 ∼ MC/N9/P9 ∼ PC) ........................................ 3-101
Fuel Level Gauge Check (KAF620M9 ∼ MC/N9/P9 ∼ PC) ............................................... 3-101
Evaporative Emission Control System (CAL Model and KAF620MB ∼/PB ∼) ........................ 3-102
Parts Removal/Installation ................................................................................................ 3-102
Hose Inspection ................................................................................................................ 3-102
Canister Inspection .......................................................................................................... 3-102
Exploded View
Exploded View
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.
Exploded View
Exploded View
Torque
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
8. KAF620MD/PD Late Models and KAF620ME/PE
9. KAF620MB ∼ MD/PB ∼ PD
10. KAF620M9 ∼ MD/N9/P9 ∼ PD
R: Replacement Parts
Exploded View (KAF620M9 ∼ MC/N9/P9 ∼ PC)
Exploded View (KAF620M9 ∼ MC/N9/P9 ∼ PC)
Torque
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)
6. KAF620M9/N9/P9, MA/PA (CAL Model)
AD: Apply adhesive.
Exploded View (KAF620MD ∼/PD ∼)
Exploded View (KAF620MD ∼/PD ∼)
Torque
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.
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:
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
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:
Input Voltage at Sensor Battery Voltage

Output Voltage at Sensor About DC 0.2 ∼ 0.4 V or DC 4.5 ∼ 4.9 V at ignition
switch ON and 0 km/h
Specifications
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
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: Measuring Adapter:
57001-125 57001-1700
Needle Adapter Set: Throttle Position Sensor Measuring Adapter:

57001-1457 57001-1719
Fuel Pressure Gauge Adapter: Liquid Gasket, TB1211:

57001-1593 56019-120
DFI System
DFI System
1. Fuel Tank 9. Water Temperature Sensor

2. Fuel Pump 10. ECU (Electronic Control Unit)
3. Subthrottle Sensor 11. Crankshaft Sensor
4. Main Throttle Sensor 12. Ignition Coils
5. Inlet Air Temperature Sensor 13. Speed Sensor
6. Subthrottle Valve Actuator 14. Air Flow
7. Inlet Air Pressure Sensor 15. Fuel Flow
8. Fuel Injectors
DFI System
DFI System Wiring Diagram
DFI System
Part Names
1. Water Temperature Sensor
2. Inlet Air Temperature Sensor
3. Fuel Injector #2
4. Subthrottle Valve Actuator
5. Subthrottle Sensor
6. Fuel Injector #1
7. Main Throttle Sensor
8. Inlet Air Pressure Sensor
9. ECU
10. Fuel Pump Relay
11. ECU Relay
12. Self-diagnosis Terminal (LG/BK) in KDS Connector
13. Fuel Pump
14. Speed Sensor
15. DFI Warning Indicator Light
16. Ignition Switch
17. Crankshaft Sensor
18. Ignition Coil #2
20. Fuse Box 1
21. ECU Relay Fuse 10 A
22. Main Fuse 30 A
23. Battery
24. Engine Ground Terminal
25. KAF620M9 ∼ MC/N9/P9 ∼ PC
○Color Codes:
BK: Black GY: Gray PU: Purple
BL: Blue LB: Light Blue R: Red
BR: Brown LG: Light Green V: Violet
CH: Chocolate O: Orange W: White
DG: Dark Green P: Pink Y: Yellow
G: Green
DFI System
Terminal Numbers of ECU Connectors
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
DFI Parts Location
Main Throttle Sensor [A]
Subthrottle Sensor [B]
Subthrottle Valve Actuator [C]
Water Temperature Sensor [D]
Inlet Air Temperature Sensor [E]
Inlet Air Pressure Sensor [A]

Fuel Injector #1 [B]
Fuel Injector #2 [C]
Ignition Coil #1 [D]
Ignition Coil #2 [E]
ECU Relay [A]

Fuel Pump Relay [B]
Fuse Box 1 [A]

Main Fuse 30 A [B]
ECU Relay Fuse 10 A [C]
Self-diagnosis Terminal (LG/BK) [A]

KDS Connector [B]
DFI Parts Location
Battery [A]
ECU [B]
Fuel Pump [A]
Crankshaft Sensor [A]
Speed Sensor [A]

DFI Parts Location
DFI Warning Indicator Light [A]
Ignition Switch [B]
[C] KAF620M9 ∼ MC/N9/P9 ∼ PC
[D] KAF620MD ∼/PD ∼
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
○This DFI system is designed to be used with a 12 V sealed

battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
○Do not reverse the battery cable connections. This will
damage the ECU.
○To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on or while the engine is running.
○Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
○When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.
○Whenever the DFI electrical connections are to be dis-

connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the con-
nector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the en-
gine.
○Connect these connectors until they click [A].
○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.
○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.
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 ∼
With the engine stopped and turned in the self-diagnosis

mode, the service code [A] is indicated by the number of
times the DFI warning indicator light blinks.
When due to a malfunction, the DFI warning indicator light
remains lit, first ask the rider about the conditions [B] of
trouble, and then determine the cause [C] of problem.
First, conduct a self-diagnosis inspection and then a
non-self-diagnosis inspection. The non-self-diagnosis
items are not indicated by the DFI warning indicator light.
Do not rely solely on the DFI self-diagnosis function, use
common sense.
Even when the DFI system is operating normally, the DFI

warning indicator light may light up under strong electrical
interference. No repair needed. Turn the ignition switch
OFF to stop the indicator light.
When the DFI warning indicator light goes on and the ve-
hicle is brought in for repair, check the service codes.
When the repair has been done, the light does not go
on. But the service codes stored in memory of the ECU are
not erased to preserve the problem history can be referred
using the KDS (Kawasaki Diagnostic System) when solving
unstable problems.
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.
• When checking the DFI parts, use a digital meter which

can be read two decimal place voltage or resistance.
○The DFI part connectors [A] have seals [B], including the
ECU. When measuring the input or output voltage with the
connector joined, use the needle adapter set [C]. Insert
the needle adapter inside the seal until the needle adapter
reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457
NOTICE
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
• Make sure that measuring points are correct in the con-

nector, noting the position of the lock [D] and the lead
color before measurement. Do not reverse connections
of a digital meter.
• Be careful not to short-circuit the leads of the DFI or elec-
trical system parts by contact between adapters.
• Turn the ignition switch ON and measure the voltage with
the connector joined.
NOTICE
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.
○After measurement, remove the needle adapters and ap-

ply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Sealant - Liquid Gasket, TB1211: 56019-120
• Always check battery condition before replacing the DFI

parts. A fully charged battery is a must for conducting
accurate tests of the DFI system.
• Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
• Measure coil winding resistance when the DFI part is cold
(at room temperature).
• Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, short,
etc. Deteriorated wires and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.
• Pull each connector [A] apart and inspect it for corrosion,

dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.
•Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect a digital meter between the ends of the leads.
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Re-
place the lead or the main harness.
○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.
○When checking a harness [A] for short circuit, open one

end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or re-
placed.
• Narrow down suspicious locations by repeating the con-

tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
DFI Diagnosis Flow Chart
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.
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:
Poor running □spark plug loose (tighten it)

or no power at □spark plug dirty, broken, or gap maladjusted (remedy it)
high speed
□spark plug incorrect (replace it)
□knocking (fuel poor quality or incorrect)
□brake dragging
□engine overheating
□engine oil level too high
□engine oil viscosity too high
□other:
DFI System Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over

Symptoms or possible Causes Actions (chapter)
Neutral switch trouble Inspect neutral switch (see chapter 17).
Crankshaft sensor trouble Inspect (see chapter 17).
Ignition coil shorted or not in good contact Inspect or Reinstall (see chapter 17).
Ignition coil trouble Inspect (see chapter 17).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Spark plug incorrect Replace it with the correct plug (see chapter 2).
ECU ground and power supply trouble Inspect (see chapter 3).
ECU trouble Inspect (see chapter 3).
No or little fuel in tank Supply fuel (see Owner’s Manual).
Fuel injector trouble Inspect and replace (see chapter 3).
Fuel pump not operating Inspect (see chapter 3).
Fuel pump relay trouble Inspect and replace (see chapter 3).
Fuel filter or pump screen clogged Replace fuel pump (see chapter 3).
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Poor Running at Low Speed

Symptoms or Possible Causes Actions (chapter)
Spark weak:
Ignition coil shorted or not in good contact Inspect or reinstall (see chapter 17).
Fuel/air mixture incorrect:
Little fuel in tank Supply fuel (see Owner’s Manual).
Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 2).
Air duct loose Reinstall (see chapter 3).
Throttle body assy holder loose Reinstall (see chapter 3).
Fuel injector O-ring damage Replace (see chapter 3).
chapter 3).
Inlet air pressure sensor trouble Inspect (see chapter 3).
Water temperature sensor trouble Inspect (see chapter 17).

Inlet air temperature sensor trouble Inspect (see chapter 3).
Main throttle sensor trouble Inspect (see chapter 3).
Subthrottle sensor trouble Inspect (see chapter 3).
Subthrottle valve actuator trouble Inspect (see chapter 3).
Unstable (rough) idling:
Fuel pressure too low or too high Inspect (see chapter 3).
Fuel injector trouble Inspect (see chapter 3).
Engine stalls easily:
Fuel pump trouble Inspect (see chapter 3).
Fuel pressure too low or too high Inspect (see chapter 3).
chapter 3).
Poor acceleration:
Fuel pressure too low Inspect (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).

Stumble:
Surge:
Unstable fuel pressure Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and repair fuel line ) (see chapter 3).
Backfiring when deceleration:
After fire:
Spark plug burned or gap maladjusted Replace (see chapter 2).
Other:
Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,
and examine leads for signs of burning or fraying
(see chapter 3).
Poor Running or No Power at High Speed:

Firing incorrect:
Ignition coil shorted or not in good contact Inspect or Reinstall (see chapter 17).

Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 2).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel injector O-ring damage Replace (see chapter 3).
Fuel injector clogged Inspect and repair (see chapter 3).
Fuel pump operates intermittently and often DFI Fuel pump bearings may wear. Replace the fuel
fuse blows. pump (see chapter 3).
Knocking:
Fuel poor quality or incorrect Fuel change (Use the gasoline recommended in
the Owner’s Manual).
Miscellaneous:
Speed sensor trouble Inspect (see chapter 3).
Throttle valves will not fully open Inspect throttle cables and lever linkage (see
chapter 3).
Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in
crankshaft sensor or speed sensor trouble chapter 18)
Exhaust Smokes Excessively:
(Black smokes)
Air cleaner element clogged Clean element (see chapter 2).
Fuel pressure too high Inspect (see chapter 3).
(Brown smoke)

Self-Diagnosis
Self-diagnosis Outline
The self-diagnosis system has two modes and can be
switched to another mode by grounding the self-diagnosis
terminal (LG/BK) in the KDS connector.
User Mode
The ECU notifies the driver of troubles in DFI system and
ignition system by lighting the DFI warning indicator light [A]
when DFI and ignition system parts are faulty, and initiates
fail-safe function. In case of serious troubles ECU stops the
injection/ignition/starter motor operation.
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
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
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.
Self-Diagnosis
• Tilt up the seat.

• Connect
Turn on the ignition switch.
• -diagnosisanterminal
auxiliary lead [A] for grounding into the self
(LG/BK) [B] in the KDS connector [C].
• -diagnosis terminal for moredealer
To enter the self-diagnosis mode, ground the self
than 2 seconds, and then
keep it grounded continuously.
• Count the blinks of the DFI warning indicator light [A] to

read the service cord.
• Keep the auxiliary lead ground until you finish reading the
service code.
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
Self-Diagnosis
Self-Diagnosis Flow Chart
Service Code Reading

○Service codes are shown by a series of long and short blinks of the DFI warning indicator lights
shown below.
○Read 10th digit and unit digit as the DFI warning indicator light blinks.
○When there are a number of problem, all the service codes can be stored and the display will be-
gin starting from the lowest number service code in the numerical order. Then after completing all
codes, the display is repeated until the self-diagnosis terminal is opened.
○For example, if four problems occurred in the order of 24, 11, 14, 13, the service codes are displayed
from the lowest number in the order listed.
(11→13→14→24) → (11→13→14→24) → (repeated)
○If there is no problem or when the repair has been done, no service code is shown.
○For example, if two problems of 12 and 24 occur, the service codes of 12 and 24 are shown as
follows.
Self-Diagnosis
Service Code Erasing
○When repair has been done, FI indicator light will not show service codes any more.
But the service codes stored in memory of the ECU are not erased to preserve the problem history.
In this model, the problem history cannot be erased.
Service Code Table
Service
DFI Warning Indicator Light Problems
Code
Main throttle sensor, subthrottle sensor
or subthrottle valve actuator malfunction,
11
wiring open or short
Subthrottle valve mechanism trouble
Inlet air pressure sensor malfunction,
12
Inlet air temperature sensor malfunction,

13
Water temperature sensor malfunction,

14
Speed sensor malfunction, wiring open or

24
short
Ignition coil #1 malfunction, wiring open or

51
short
Ignition coil #2 malfunction, wiring open or

52
short
Notes:
○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
○When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
Self-Diagnosis
Backups
○The ECU takes the following measures to prevent engine damage when the DFI or ignition system
parts have troubles.
Service Output Signal Usable
Parts Backups by ECU
Codes Range or Criteria
If the throttle sensor system fails (the output
Main Throttle
voltage is out of the usable range, wiring
Sensor
short or open), the ECU locks at the particular
Subthrottle Throttle Sensor Output
ignition timing and stops ignition and fuel
11 Sensor Voltage
injection of the #2 cylinder. Subthrottle valve
Subthrottle 0.2 ∼ 4.8 V
is locked the specified angle by the subthrottle
Valve
valve actuator that receives the signal from
Actuator
the ECU.
If the inlet air pressure sensor system fails
Inlet Air Inlet Air Pressure
(the signal is out of the usable range, wiring
12 Pressure (Absolute)
short or open), the ECU sets the DFI in the
Sensor Pv = 100 ∼ 900 mmHg
α-N method.
Inlet Air If the inlet air temperature sensor system fails
Inlet Air Temperature
13 Temperature (the signal is out of the usable range, wiring
Ta = – 30 ∼ + 120°C
Sensor short or open), the ECU sets Ta at 40°C.
If the water temperature sensor system fails
Water
Water Temperature (the signal is out of the usable range, wiring
14 Temperature
Tw = – 30 ∼ + 120°C short or open), the ECU sets Tw at 98.1°C and
Sensor
the radiator fan operates.
Speed sensor must send
Speed 18 signals to the ECU at If the speed sensor system fails (no signal,
24
Sensor the 1 rotation of the output wiring short or open), the ECU sets 10 km/h.
shaft.
The ignition coil primary
Ignition Coil winding must send
51 —
#1* signals 20 or more times
continuously to the ECU.
The ignition coil primary
Ignition Coil winding must send
52 —
#2* signals 20 or more times
continuously to the ECU.
○Usually, the DFI of this model is controlled to D-J method by ECU.

Note:
D-J Method: The ECU determines the injection quantity by calculating from the throttle vacuum
(inlet air pressure sensor output voltage) and engine speed (crankshaft sensor output pulse).
α-N Method: The ECU determines the injection quantity by calculating from the throttle opening
(subthrottle sensor output voltage) and the engine speed.
*: This depends on the number of stopped cylinders.
Main Throttle Sensor, Subthrottle Sensor and Subthrottle Valve Actuator (Ser-
vice Code 11)
Troubleshooting Guide of Service Code 11
ECU stores the Code 11 when below failure(s) are detected:
• Abnormal output voltage of the main throttle sensor
• Abnormal output voltage of the subthrottle sensor
• Subthrottle valve actuator malfunction
Inspect the related parts as following.
Main Throttle Sensor Removal
NOTICE
Never drop the main throttle sensor, especially on
a hard surface.
Such a shock to the main throttle sensor can dam-
age it.

• Remove: the main throttle sensor connector [A].
Disconnect
• Main Throttle Sensor Screws [B]
Main Throttle Sensor [C]
Main Throttle Sensor Installation

• Replace the seal [A] with a new one.
•○When installing
Install the seal and lip seal [B] to the main throttle sensor.
the lip seal, the large diameter faces the
sensor.
• Apply fluoridated grease (Daikin: Demnum grease L-200)

[A] so that the cover the verge of the lip seal and rotor.
vice Code 11)
• Confirm the main throttle sensor collar [A] is installed cor-

rectly into the throttle body before installing the throttle
sensor.
•Align the sensor with the throttle shaft [B] and insert the
sensor fully into the throttle body.
○Position the sensor connector upward.
• 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.
• Disconnect the main throttle sensor connector and con-

nect the throttle position sensor measuring adapter [A]
between the harness connector [B] and sensor [C].
Special Tool - Throttle Position Sensor Measuring
Adapter: 57001-1719
• Set a digital voltage meter to DC 0.00V, and connect the
meter lead to the measuring adapter.
• Turn the ignition switch ON.
• Measure each throttle sensor output voltage.
Reading 1:
Digital Meter (+) → Harness Lead (BR/BL) [A]
Digital Meter (–) → Harness Lead (BR/BK) [B]
Reading 2:
Digital Meter (+) → Harness Lead (BR/R) [C]
• Compare the measured values of Reading 1 and Reading

2, and determine which of the two voltages is lower.
vice Code 11)
• 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
○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].
• Connect the measuring adapter [A] between the main har-

ness connector [B] and main throttle sensor [C].
Adapter: 57001-1719
• Connect a digital meter to the measuring adapter leads.
Connections:
Digital Meter (+) → BL/R lead of Main Harness
Digital Meter (–) → BR/BK lead of Main Harness

Main Throttle Sensor Input Voltage
Standard: DC 4.75 ∼ 5.25 V

If the reading is within the standard, check the output volt-
age (see Main Throttle Sensor Output Voltage Inspec-
tion).
vice Code 11)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
• Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
BL/R lead (ECU terminal 5) [C]
BR/BK lead (ECU terminal 24) [D]
If the wiring is not good, replace the main harness.
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
vice Code 11)
Main Throttle Sensor Output Voltage Inspection
• Measure the output voltage at the main throttle sensor
in the same way as input voltage inspection. Note the
following.
nect the measuring adapter [A] between the main harness
connector [B] and main throttle sensor [C].
Adapter: 57001-1719
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
Harness
• Check to see that the throttle lever contacts the stop

screw (see Main Throttle Sensor Installation) for throttle
closing.
Standard: DC 0.89 ∼ 1.13 V at throttle closing
DC 3.81 ∼ 4.11 V at full throttle opening
(reference value)
○The difference of the measurement value of (I) and (II) is
within 0.22 V.
NOTE
○Open the throttle, confirm the output voltage will be
raise.
○The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
0.89 × 4.75 ÷ 5.00 = 0.85 V
1.13 × 4.75 ÷ 5.00 = 1.07 V
Thus, the valid range is 0.85 ∼ 1.07 V

If the reading is out of the standard, check the main throt-
tle sensor resistance (see Main Throttle Sensor Resis-
tance Inspection).
vice Code 11)
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
(l) BR/BL lead (ECU terminal 6) [C]
(ll) BR/R lead (ECU terminal 22) [D]
BR/BK lead (ECU terminal 24) [E]
If the ground and power supply are good, inspect the sub-
throttle sensor.
Main Throttle Sensor Resistance Inspection
• Connect a digital
Disconnect the main throttle sensor connector.
• connector [B]. meter [A] to the main throttle sensor
• Measure the main throttle sensor resistance.
Main Throttle Sensor Resistance
Connections: Terminal [C] ←→Terminal [D]
Standard: Approx. 2.7 kΩ
Connections: Terminal [D] ←→Terminal [E]
If the reading is out of the standard, replace the main
throttle sensor (see Main Throttle Sensor Installation).
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Removal
NOTICE
Never drop the subthrottle sensor, especially on a
hard surface. Such a shock to the subthrottle sen-
sor can damage it.

• Remove: the subthrottle sensor connector [A].
Disconnect
• Subthrottle Sensor Screws [B]
Subthrottle Sensor [C]
vice Code 11)
Subthrottle Sensor Installation
• Replace the seal [A] with a new one.
•○Install the seal and lip seal [B] to the subthrottle sensor.
When installing the lip seal, the large diameter faces the
sensor.
• Apply fluoridated grease (Daikin: Demnum grease L-200)

[A] so that it covers the verge of the lip seal and rotor.
• Confirm the subthrottle sensor collar [A] is installed cor-

rectly into the throttle body before installing the subthrottle
sensor.
•Align the sensor with the subthrottle shaft [B] and insert
the sensor fully into the throttle body.
○Position the sensor connector upward.
• 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]
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.
• Connect the throttle position sensor measuring adapter

[A] between the harness connector [B] and sensor [C].
Adapter: 57001-1719
• Set a digital voltage meter to DC 0.00 V, and connect the
• Turn the subthrottle lever [A] counterclockwise with your

finger and contact the subthrottle lever to the stop screw
[B].
NOTE
○Do not adjust the position of the stop screw [B]. If the
stop screw has been adjusted, replace the throttle body
assembly.

• Measure each subthrottle sensor output voltage.
Reading 1:
Digital Meter (+) → Harness Lead (Y/W) [A]
Reading 2:
Digital Meter (+) → Harness Lead (Y/R) [C]

2, and determine which of the two voltages is higher.
vice Code 11)
• Adjust [A] the position of the sensor [B] until the higher
of two voltage readings meets below Subthrottle Sensor
Subthrottle Sensor Output Voltage
Example:
○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)
• Remove the measuring adapter and reconnect the sensor
connector.
• Make sure the actuator cover seal [A] is in place.

• Tighten:the actuator cover.
Install
•
Torque - Subthrottle Valve Actuator Cover Screws: 2.0 N·m
(0.20 kgf·m, 18 in·lb)
• Tighten:
Torque - Control Panel Cover Bolts: 4.0 N·m (0.41 kgf·m, 35
in·lb)
Subthrottle Sensor Input Voltage Inspection

NOTE
• Disconnect
• the subthrottle sensor connector [A].
vice Code 11)

ness connector [B] and subthrottle sensor [C].
Adapter: 57001-1719
Subthrottle Sensor Input Voltage
Connections to Adapter:

Input Voltage

age (see Subthrottle Sensor Output Voltage Inspection).

connectors.
Subthrottle Sensor Connector [B]
Subthrottle Sensor Output Voltage Inspection
• Measure the output voltage at the subthrottle sensor in
the same way as input voltage inspection. Note the fol-
lowing.
•Remove:
Subthrottle Valve Actuator Cover (see Subthrottle Sen-
sor Removal)
○Do not remove the subthrottle valve actuator lead con-
nector.
vice Code 11)
• Disconnect the subthrottle sensor connector and connect

the measuring adapter [A] between the main harness con-
nector [B] and subthrottle sensor [C].
Adapter: 57001-1719
(l) Digital Meter (+) → Y/R lead of Main Harness
BR/BK lead of Main
Harness
(ll) Digital Meter (+) → Y/W lead of Main Harness
BR/BK lead of Main
Harness
• Turn the subthrottle lever [A] counterclockwise with your

finger and contact the subthrottle lever to the stop screw
[B] (see Subthrottle Sensor Installation) for the subthrottle
valve closing.
vice Code 11)
• Turn the subthrottle lever [A] clockwise with your finger

and contact the subthrottle lever to the stopper [B] for the
subthrottle valve opening.
Subthrottle Sensor Output Voltage
Standard: DC 0.58 ∼ 0.82 V at subthrottle valve
closing
DC 3.81 ∼ 4.11 V at subthrottle valve
opening (reference value)
○The difference of the measurement value of (I) and (II) is
within 0.22 V.
NOTE
○Open the throttle, confirm the output voltage will be
raise.
○The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
○Example:
In the case of a input voltage of 4.75 V.
0.58 × 4.75 ÷ 5.00 = 0.55 V
0.82 × 4.75 ÷ 5.00 = 0.78 V
Thus, the valid range is 0.55 ∼ 0.78 V

If the reading is out of the standard, check the subthrot-
tle sensor resistance (see Subthrottle Sensor Resistance
Inspection).
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness con-
nectors.
Subthrottle Sensor Connector [B]
(l) Y/R lead (ECU terminal 21) [C]
(ll) Y/W lead (ECU terminal 4) [D]
BR/BK lead (ECU terminal 24) [E]
If the ground and power supply are good, inspect the sub-
throttle valve actuator.
vice Code 11)
Subthrottle Sensor Resistance Inspection
• Disconnect the subthrottle sensor connector.
• nector [B].
Connect a digital meter [A] to the subthrottle sensor con-
• Measure the subthrottle sensor resistance.

Subthrottle Sensor Resistance
Connections: Terminal [C] ←→Terminal [D]
Connections: Terminal [D] ←→Terminal [E]
If the reading is out of the standard, replace the subthrottle
sensor (see Subthrottle Sensor Installation).
Subthrottle Valve Actuator Removal
NOTICE
Do not remove the subthrottle valve actuator [A]
since it has been adjusted and set with precision
at the factory.
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the subthrottle valve
actuator can damage it.
Subthrottle Valve Actuator Resistance Inspection

• Disconnect the subthrottle valve actuator connector [A].
• Connect a digital meter to the subthrottle valve actuator

connector [A].
• Measure the subthrottle valve actuator resistance.
Subthrottle Valve Actuator Resistance
Connections: Each Terminal [B] ←→ Terminal [C]
Standard: Approx. 120 Ω at 25°C (77°F)
If the reading is out of the standard, replace the throttle
body assy.
exists, inspect the subthrottle valve mechanism.
vice Code 11)
Subthrottle Valve Mechanism Inspection
○Even when the subthrottle valve doesn’t reach the target
opening for trouble of the subthrottle valve actuator, sub-
throttle sensor or subthrottle valve mechanism, the ser-
vice code 11 will appear.
• When the subthrottle valve actuator and subthrottle sen-
sor are good, inspect the subthrottle valve actuator as fol-
lows.
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal)
Subthrottle Valve Actuator Cover (see Subthrottle Sen-
sor Installation)
• Visually
[A].
inspect the subthrottle valve actuator mechanism
If the mechanism is damaged, replace the throttle body

assy.
• 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.
vice Code 11)
Throttle Sensors and Subthrottle Valve Actuator Circuit
1. ECU
5. Power Source
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: the inlet air pressure sensor connector [A].
Disconnect
• Control Panel Assembly [B] (see Control Panel Assem-
bly Removal)
• Remove:
Inlet Air Pressure Sensor [A] (Upward)
Inlet Air Pressure Sensor Installation

• Be sure to install the nozzle seat [A].
• Push down the inlet air pressure sensor [B] and install it.
• Control Panel Assembly (see Control Panel Assembly
Install:
Installation)
Inlet Air Pressure Sensor Input Voltage Inspection

NOTE
• Disconnect
• the inlet air pressure sensor connector [A].

ness connector [B] and inlet air pressure sensor [C].
Special Tool - Measuring Adapter: 57001-1700
Connections:

Inlet Air Pressure Sensor Input Voltage

age (see Inlet Air Pressure Sensor Output Voltage Inspec-
tion).
connectors.
Inlet Air Pressure Sensor Connector [B]
Inlet Air Pressure Sensor Output Voltage
Inspection
• Measure the output voltage at the inlet air pressure sensor
in the same way as input voltage inspection. Note the
following.
• Disconnect the inlet air pressure sensor connector and

connect the measuring adapter [A] between the main har-
ness connector [B] and inlet air pressure sensor [C].
Connections:
Digital Meter (+) → G/Y lead of Main Harness

Inlet Air Pressure Sensor Output Voltage
Usable Range: DC 3.46 ∼ 3.82 V at standard
atmospheric pressure (101.32 kPa,
76 cmHg)
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

If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
Inlet Air Pressure Sensor Circuit
1. ECU
2. Inlet Air Pressure Sensor
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.

• Pull out the inlet
Disconnect the inlet air pressure sensor connector [A].
• met. air temperature sensor [B] from the grom-
Inlet Air Temperature Sensor Installation

• Push the sensor [A] into the grommet [B] until the flange
[C] of sensor touches to the grommet, and locks knob [D].
Inlet Air Temperature Sensor Output Voltage

Inspection
NOTE
• Disconnect
• the inlet air temperature sensor connector [A].

ness connector [B] and inlet air temperature sensor [C].
Connections:
Digital Meter (+) → R lead of Main Harness

Inlet Air Temperature Sensor Output Voltage
Standard: About DC 2.0 ∼ 2.5 V at 20°C (68 °F)

If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply In-
spection).
Inlet Air Temperature Sensor (Service Code 13)
connectors.
Inlet Air Temperature Sensor Connector [B]
R lead (ECU terminal 18) [C]
If the wiring is good, check the inlet air temperature sensor
resistance (see Inlet Air Temperature Sensor Resistance
Inspection).
Inlet Air Temperature Sensor Resistance
Inspection
• Remove the inlet air temperature sensor (see Inlet Air
Temperature Sensor Removal/Installation).
• Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion is submerged.
• Suspend a thermometer [B] with the heat-sensitive por-
tion [C] located in almost the same depth with the sensor.
NOTE
○The sensor and thermometer must not touch the con-
tainer side or bottom.
• Place the container over a source of heat and gradually

raise the temperature of the oil while stirring the oil gently
for even temperature.
• Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the following.
Inlet Air Temperature Sensor Resistance
Standard: 2.21 ∼ 2.69 kΩ at 20°C (68 °F)
0.290 ∼ 0.354 kΩ at 80°C (176 °F) (reference
value)
If the reading is out of the standard, replace the sensor.
Inlet Air Temperature Sensor Circuit
1. ECU
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.

• Maintenance
Drain the coolant (see Coolant Change in the Periodic
chapter).
• Disconnect the water temperature sensor connector [A].
• Water Temperature Sensor [B]
Remove:
Water Temperature Sensor Installation

• Apply silicone sealant to the threads of the water temper-
ature sensor [A].
• Replace
washer.
the washer [B] and install the sensor with new
• 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
• Disconnect
• the water temperature sensor connector [A].
Water Temperature Sensor (Service Code 14)

ness connector [B] and water temperature sensor [C].
Connections:
Digital Meter (+) → O lead of Main Harness

Water Temperature Sensor Output Voltage
Standard: About DC 2.0 ∼ 2.5 V at 20°C (68 °F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.

If the reading is within the standard, check the ECU for
spection).
connectors.
Water Temperature Sensor Connector [B]
O lead (ECU terminal 1) [C]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
• Refer to the Water Temperature Sensor Inspection in the
Electrical System chapter.
Water Temperature Sensor Circuit
1. ECU
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.

• Remove: the speed sensor connector [A].
Disconnect
• Speed Sensor Bolt [B]
Speed Sensor [C]
Speed Sensor Installation

• Replace the O-ring [A] with a new one.
• Install the speed
Apply grease to the O-ring.
• before tightening the
sensor [B] to the fully seated position
mounting bolt.
NOTE
○If the sensor is not fully seated before tightening the bolt,
the O-ring can be damaged and oil may leak.
• Tighten:
Torque - Speed Sensor Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Speed Sensor Input Voltage Inspection

NOTE
• Disconnect
• the speed sensor connector [A].

ness connector [B] and speed sensor [C].
• Connect
leads.
a digital meter [D] to the measuring adapter
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-
Speed Sensor Input Voltage

Standard: Battery Voltage

age (see Speed Sensor Output Voltage Inspection).

connectors.
Speed Sensor Connector [B]
BK lead (ECU terminal 29) [C]
Speed Sensor Output Voltage Inspection
• Before this inspection, inspect the input voltage (see
Speed Sensor Input Voltage Inspection).
• Raise the rear wheel off the ground.
• Measure the output voltage at the speed sensor in the

same way as input voltage inspection, and note the fol-
lowing.
• Disconnect the speed sensor connector and connect the
measuring adapter [A] between these connectors.
Main Harness Connector [B]
Speed Sensor [C]
• Connect a digital meter [D] to the measuring adapter
leads.
Connections:
Digital Meter (+) → P lead of Main Harness
Digital Meter (–) → BK lead of Main Harness
• Turn
age.
the ignition switch ON and measure the output volt-
• Rotate the rear wheel by hand, and confirm whether the

output voltage rises or lowers.
Speed Sensor Output Voltage
Standard: About DC 0.2 ∼ 0.4 V or DC 4.5 ∼ 4.9 V at
ignition switch ON and 0 km/h

If the reading is out of the standard, replace the sensor.
If the reading is out of the standard, check the wiring for
continuity between main harness connectors.
Speed Sensor Connector [B]
P lead (ECU terminal 12) [C]
Speed Sensor Circuit
1. ECU
2. Speed Sensor
3. Power Source
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
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
•○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.
Ignition Coil Input Voltage

Connections to ECU Connector:
For Ignition Coil #1
Digital Meter (+) → BL lead (terminal 17)
Digital Meter (–) → Battery (–) terminal
For Ignition Coil #2
Digital Meter (+) → W lead (terminal 16)
• Measure the input voltage to each primary winding of the

ignition coils with the engine stopped, and with the con-
nectors joined.
Input Voltage

If the input voltage is out of the standard, check the wiring
for continuity (see wiring diagram in this section).
If the input voltage is within the standard, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
Ignition Coils #1, #2 (Service Code 51, 52)
Ignition Coil Circuit
1. Ignition Switch
2. ECU
4. Battery
5. Fuse Box 1
6. Main Fuse 30 A
7. Ignition Coil #1
8. Ignition Coil #2
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
•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.
DFI Warning Indicator Light Input Voltage

Inspection
NOTE
• Front Cargo Compartment (see Front Cargo Compart-
Remove:

• Disconnect the DFI warning indicator light lead connector
[A].
• Connect a tester [A] to the main harness connector [B].

Connections:
Tester (+) → W/Y lead of connector
Tester (–) → LG/G lead of connector

DFI Warning Indicator Light Input Voltage
Standard: Battery Voltage (Two Seconds)

If the reading is within the standard, replace the bulb (see
Indicator Light Bulb Replacement in the Electrical System
chapter).
If the reading is out of the standard, check the ECU for
spection).
DFI Warning Indicator Light
DFI Warning Indicator Light Circuit

2. Ignition Switch
3. ECU Relay
4. ECU
5. Battery
6. Fuse Box 1
7. Main Fuse 30 A
ECU
ECU Removal
NOTICE
Never drop the ECU, especially on a hard surface.
Such a shock to the ECU can damage it.
• 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)
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.

• Visually inspect
Disconnect the ECU connector.
• If the terminals ofthetheterminals [A] of the ECU connectors.
main harness connectors are dam-
aged, replace the main harness.
If the terminals of the ECU connectors are damaged, re-
place the ECU.
ECU
○Disconnect the ECU connector [A].
• following
Set a digital meter [B] to the × 1 Ω range and check the
wiring for continuity.
ECU Grounding Inspection
7 (BK/Y) Terminal ←→ Battery (–) Terminal: 0 Ω
34 (BK/Y) Terminal ←→ Battery (–) Terminal: 0 Ω
Engine Ground ←→ Battery (–) Terminal: 0 Ω
If no continuity, check the connectors, the engine ground

lead, or main harness, and repair or replace them if nec-
essary.
If the wiring is good, check the power source voltage of
the ECU.
• Connect the ECU connector.
• Install the battery temporarily.
NOTE
needle adapter set.
ECU Power Supply Inspection

Connections:
(I) Digital Meter (+) → Terminal 3 (W/Y)
(II) Digital Meter (+) → Terminal 8 (W)
Ignition Switch OFF:
(I) Terminal 3 (W/Y): 0 V
(II) Terminal 8 (W): Battery Voltage
Ignition Switch ON:
(II) Terminal 3 (W/Y): Battery Voltage
(II) Terminal 8 (W): Battery Voltage
If the reading is out of the specification, check the follow-
ing.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
ECU Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Power Source Wiring (see wiring diagram in this section)
If the fuse and wiring are good, replace the ECU (see ECU
Removal/Installation).
ECU
ECU Power Source Circuit
1. Ignition Switch
2. ECU Relay
3. ECU
4. Battery
5. Fuse Box 1
6. Main Fuse 30 A
DFI Power Source
ECU Relay Fuse Removal
• Refer
ter.
to the Fuse Removal in the Electrical System chap-
ECU Relay Fuse Installation

If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
• Refer to the Fuse Installation in the Electrical System
chapter.
ECU Relay Fuse Inspection
• Refer to the Fuse Inspection in the Electrical System
chapter.
ECU Relay Removal
NOTICE
Never drop the relay, especially on a hard surface.
Such a shock to the relay can damage it.

• nect the connector.
Remove the ECU relay [A] from the tongue and discon-
ECU Relay Inspection

• Remove:
ECU Relay (see ECU Relay Removal)
• relay [C] aasdigital
Connect
shown.
meter [A] and a 12 V battery [B] to the
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 Line
Fuel Pressure Inspection
NOTE
• 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
• Install the fuel pressure gauge adapter [A] and suitable

fuel hoses [B] between the fuel outlet pipe and delivery
pipe.
• Secure the fuel hoses with the clamps.
• Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
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.
•○Turn the ignition switch ON.

The fuel pump should operate for 3 seconds, and then
should stop.
NOTE
○After turning on the engine stop switch and ignition
switch, inspect the fuel leakage from the connected
portion of the special tools.
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.
• Start the engine, and let it idle.

• Measure the fuel pressure with the engine idling.
Fuel Pressure (with Engine Idling)
Standard: 285 ∼ 315 kPa (2.9 ∼ 3.2 kgf/cm², 41 ∼ 46 psi)
Fuel Line
NOTE
○The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.

If the fuel pressure is much higher than specified, replace
the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Fuel Line Leakage
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
• After above checks, measure the fuel pressure again.
• Remove the fuel pressure gauge, hoses and adapter.
• Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
• Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
WARNING
plosive under certain conditions, creating the
potential for serious burns. Make sure the area is
well-ventilated and free from any source of flame
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
NOTE
• 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 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.
• Close the fuel tank cap.

•○Turn the ignition switch ON.
The fuel pump should operate for 3 seconds, and then
should stop.
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.
•○Measure the discharge for 3 seconds.

Repeat this operation several times.
Amount of Fuel Flow
Standard: 50 mL (1.7 US oz.) or more for 3 seconds

If the fuel flow is much less than the specified, replace the
fuel pump (see Fuel Pump Removal/Installation).
• Start the engine and check for fuel leakage.
Fuel Pump
Fuel Pump Removal
WARNING
Disconnect the battery (–) terminal. To avoid fuel
spills, draw it from the tank when the engine is
cold. Be prepared for fuel spillage; any spilled fuel
must be completely wiped up immediately.
NOTICE
Never drop the fuel pump, especially on a hard sur-
face. Such a shock to the pump can damage it.

• available
Draw the fuel out from the fuel tank with a commercially
electric pump.
• 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 ∼
• Discard the O-ring [A].

Fuel Pump
Fuel Pump Installation
• Remove dirt or dust from the fuel pump [A] by lightly ap-
plying compressed air.
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
• Replace the O-ring with a new one.
• 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)
Fuel Pump Operation Inspection

NOTE
○Just listen to the pump sound in the fuel tank to confirm
pump operation.
• Turn the ignition switch ON and make sure that the fuel
pump operates (make light sounds) for 3 seconds, and
then stops.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
Fuel Pump
Fuel Pump Operating Voltage Inspection
NOTE
• 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]
• Connect
leads.
a digital meter [D] to the measuring adapter
[E] KAF620M9 ∼ MC/N9/P9 ∼ PC

[F] KAF620MD ∼/PD ∼
Fuel Pump Operating Voltage
Digital Meter (+) → BK/BL lead of Main Harness
Digital Meter (–) → BK/Y lead of Main Harness
• Measure the operating voltage with engine stopped and

with the connector joined.
Operating Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V

If the reading stays on battery voltage and never shows
0 V, check the fuel pump relay (see Fuel Pump Relay
Inspection).
If the fuel pump relay is normal, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If there is still no battery voltage, check the fuel pump relay
(see Fuel Pump Relay Inspection).
If the fuel pump relay is normal, check the wiring for con-
tinuity (see wiring diagram in this section).
If the reading is in specification, but the pump does not op-
erate, replace the fuel pump (see Fuel Pump Removal/In-
stallation).
Fuel Pump
Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump and
can not be removed.
[B] KAF620M9 ∼ MC/N9/P9 ∼ PC
Fuel Filter Cleaning (KAF620M9 ∼ MC/N9/P9 ∼ PC)

○The fuel filters [A] are built into the pump and can not be
cleaned or checked.
If the fuel filters are suspected of clogging or being dam-
aged, replace the fuel pump assembly.
Fuel Filter Cleaning (KAF620MD ∼/PD ∼)

WARNING
burns. Clean the fuel filter in a well-ventilated area,
and take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low flash-point solvents to clean the fuel filter.
• 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.
Fuel Pump
Fuel Pump Relay Removal
NOTICE

• Remove the fuel pump relay [A] from the tongue and dis-
connect the connector.
Fuel Pump Relay Inspection

• Remove:
Fuel Pump Relay (see Fuel Pump Relay Removal)
• relay [C] aasdigital
Connect
shown.
meter [A] and a 12 V battery [B] to the
Testing Relay
Fuel Pump
Fuel Pump Circuit (KAF620M9 ∼ MC/N9/P9 ∼ PC)
1. Ignition Switch 6. Battery

2. ECU Relay 7. Fuse Box 1
3. Fuel Pump Relay 8. Main Fuse 30 A
4. ECU 9. ECU Relay Fuse 10 A
5. Fuel Pump
Fuel Pump
Fuel Pump Circuit (KAF620MD ∼/PD ∼)
1. Ignition Switch 6. Battery

2. ECU Relay 7. Fuse Box 1
3. Fuel Pump Relay 8. Main Fuse 30 A
4. ECU 9. ECU Relay Fuse 10 A
5. Fuel Pump
Fuel Injectors
Fuel Injector Removal
• Remove:
Control Panel
Inlet Air Pressure Sensor (see Inlet Air Pressure Sensor
Removal)
Fuel Injectors Connectors [A]
• Disconnect the fuel hose [B] (see Fuel Hoses Replace-
ment in the Periodic Maintenance chapter).
• Remove:
Bolts [C]
Fuel Pipe [D]
• 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].
Fuel Injector Installation

• Apply grease to the O-ring.
• 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.
Fuel Injectors
Fuel Injector Audible Inspection
NOTE
• 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.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
Fuel Injector Resistance Inspection

• Disconnect the fuel injector connector [A] and connect the
measuring adapter [B] to the fuel injector [C].
• Connect a digital meter to the measuring adapter.
• Measure the fuel injector resistance.
Fuel Injector Resistance
Standard: About 11.7 ∼ 12.3 Ω at 20°C (68°F)
If the reading is out of the standard, replace the fuel in-
jector.
If the reading within the standard, check the power source
voltage (see Fuel Injector Power Source Voltage Inspec-
tion).
Fuel Injectors
Fuel Injector Power Source Voltage Inspection
NOTE
• Disconnect
• suring adapter
the injector connector and connect the mea-
[A] between these connectors as shown in
the figure.
Main Harness [B]
Fuel Injector #1 [C]
• Connect a digital meter [D] to the measuring adapter lead.
Fuel Injector Power Source Voltage
Fuel Injector #1, #2
Digital Meter (+) → W/Y lead of Main Horness
• Measure
stopped.
the power source voltage with the engine

Power Source Voltage

If the reading is not battery voltage, check the power
source wiring (see wiring diagram in this section).
If the reading is in specification, check the output voltage
(see Fuel Injector Output Voltage Inspection).
Fuel Injectors
Fuel Injector Output Voltage Inspection
NOTE
•○Do not disconnect
Remove the ECU (see ECU Removal).
the ECU connector.
needle adapter set.
Fuel Injector Output Voltage

Connections to ECU Connector:
For Fuel Injector #1
Digital Meter (+) → O/R lead (ECU terminal 15)
Digital Meter (+) → O/G lead (ECU terminal 14)
• Measure the output voltage with the engine stopped and

with the connector joined.
Output Voltage

If the reading is in specification, check the ECU for its
ground and power supply (see ECU Power Supply In-
spection).
If the reading is out of the specification, remove the ECU
connector.
○Disconnect the ECU and injector connector.
ECU Connector [A] ←→ Fuel Injector Connector [B]
O/R lead (ECU terminal 15) [C]
O/G lead (ECU terminal 14) [D]
Fuel Injectors
Fuel Injector Circuit
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
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
Full Throttle Pedal Position Adjustment
• Refer to the Full Throttle Pedal Position Adjustment in the
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.
Throttle Cable Lubrication and Inspection

• Whenever the throttle cable is removed or in accordance
with the Periodic Maintenance Chart in the Periodic Main-
tenance chapter, lubricate the cable .
• Refer to the General Lubrication in the Periodic Mainte-
nance chapter.
Control Panel
Control Panel Removal
• 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].
• Remove:
Throttle Cable End [D]
Inlet Air Pressure Sensor Connector [E]
Bolts [F]
Control Panel [G]
Control Panel Installation

• Installation is reverse of removal.
• Before installing the control panel, check to see that the
throttle lever [A] moves smoothly in all directions.
If any part is worn or damaged, replace it.
• When installing the throttle link rod, install the rod end in
the throttle pulley first.
• Tighten:
Torque - Control Panel Cover Bolts: 4.0 N·m (0.41 kgf·m, 35
in·lb)
• After installation, check that the idle speed is within the
specified range (see Idle Speed Inspection in the Periodic
Control Panel Disassembly
NOTE
○When the throttle lever mounting nut [A] is removed,
the nut and control panel [B] must be changed with new
ones.
○The idle speed is controlled by ECU. Therefore do not
adjust the throttle lever stopper screw [C]. If the screw
is turned, the idle speed is changed.
○If the throttle lever stopper screw is removed, adjust
the position when installing the screw (see Idle Speed
Inspection in the Periodic Maintenance chapter).
• Remove:
Control Panel (see Control Panel Removal)
Spring [D]
Throttle Lever Mounting Nut
Washers
Throttle Lever [E]
Washer
Control Panel
Control Panel
• When removing the ball bearing [A], use a press and dis-
card the bearing.
Control Panel Assembly

• When installing the ball bearing [A], press the ball bearing
until the flange [B] of the bearing contacts with the throttle
lever [C].
• Replace the throttle lever mounting nut [A] and control

panel [B] with new ones.
• Install:
Control Panel
Washer (6.2 × 10 × 0.5) [C] (P/No. 92200-2083)
Throttle Lever [D]
Washer (6.2 × 10 × 0.5) [E] (P/No. 92200-2083)
Washer (6.5 × 16 × 1.6) [F] (P/No. 92022-2247)
Ball Bearing [G]
Throttle Lever Mounting Nut
• Tighten:
Torque - Throttle Lever Mounting Nut: 6.9 N·m (0.70 kgf·m,
61 in·lb)
• Install the spring [H] in the direction of figure as shown.
• the Throttle LevertheStopper
When installing throttle lever stopper screw [I], refer to
Screw Position in the Periodic
Maintenance chapter.
• Check the idle speed (see Idle Speed Inspection in the
Periodic Maintenance chapter).
Throttle Body Assy
Idle Speed Inspection/Adjustment
• Refer to the Idle Speed Inspection/Adjustment in the Pe-
riodic Maintenance chapter.
Throttle Body Assy Removal
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
NOTICE
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the body assy can
damage it.
• Drain the coolant (see Coolant Change in the Periodic

KAF620ME/PE
•Remove:
Breather Mounting Bolt [A]
Clamp [B]
Washer [C]
Collar [D]
Dipstick Pipe Bolt [E]
Washer [F]
Collar [G]
Clamp [H]
Breather [I]
•Disconnect:
Breather Hose [J]
Crankcase Breather Hose [K]
• 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:
Subthrottle Sensor Connector [C]
Subthrottle Valve Actuator Connector [D]
Fuel Injector Connectors [E]
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]
• Slide the throttle body assy [A] to right side [B].

• Band [C]
Remove:
Inlet Manifold Bolts [D]
• Lift up the inlet manifold [A], and remove the inlet pipe [B]
and throttle body assy [C].
Throttle Body Assy Installation

• Clean the mating surfaces of the cylinder head, inlet man-
ifold, throttle body assy and inlet pipe.
• Install the following parts to the inlet manifold temporarily.
New Gaskets
Throttle Body Assy [A]
Inlet Pipe [B]
○Install the gasket that has the projections [C] on the inlet
manifold side.
Throttle Body Assy
• Install:
New Gaskets
Inlet Manifold [A]
• Tighten the inlet manifold bolts following the tightening
sequence.
Throttle Body Side [B]
• Install the band [A] with the harnesses.

• Inlet Pipe Nuts
Tighten:

• Idle Speed (see Idle Speed Inspection in the Periodic
Check:
Throttle Pedal Free Play (see Throttle Pedal Free Play
Inspection in the Periodic Maintenance chapter)
Stop Screw Replacement

NOTE
○Do not adjust the stop screw [A] because it is adjust or
set surely at the manufacturer. Adjustment of this part
could result in poor performance.
○However, when replacing the screw with a new one,
install it according to either of the following procedures.
When the main throttle sensor is specified position.

•Tilt up the cargo bed.
•Loosen the locknut [A] and remove the stop screw [B], and
then install a new stop screw and locknut temporarily.

nect the throttle position sensor measuring adapter [A]
between the harness connector [B] and main throttle sen-
sor [C].
Adapter: 57001-1719
• Set a digital voltage meter to DC 0.00V, and connect the
Throttle Body Assy
• Measure each throttle sensor output voltage.

Reading 1:
Digital Meter (+) → Harness Lead (BR/BL) [A]
Reading 2:
Digital Meter (+) → Harness Lead (BR/R) [C]

2, and determine which of the two voltages is lower.
• Adjust the position of the stop screw [A] until the lower of
two voltage readings meets below Main Throttle Sensor
Example:
○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.
• Remove
connector.
the measuring adapter and reconnect the sensor
• Install the control panel cover (see Throttle Body Assy

Installation).
When the main throttle sensor is not specified position.
•Tilt up the cargo bed.
•Loosen the locknut [A] and remove the stop screw [B], and
then install a new stop screw and locknut temporarily.
•Remove:
Inlet Pipe [C] (see Throttle Body Assy Removal)
Throttle Body Assy
• 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.).
[B] Fully Closed Position

[C] 6.2°
[D] Clearance 0.37 mm (0.0146 in.)
[E] Engine Side
[F] Upper Side
• 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)
Inlet Manifold
Inlet Manifold Removal
• 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.
Air Cleaner
Air Cleaner Element Cleaning
• Refer to the Air Cleaner Element Cleaning in the Periodic
Air Cleaner Housing Removal
• Remove:
Air Ducts [A]
Air Cleaner Housing Bolts [B]
Air Cleaner Housing [C]
Air Cleaner Housing Installation

•ForInstall the air ducts and tighten the clamp screws.
KAF620M9/N9/P9, MA/PA
• screw insealant
Apply to the area [A] shown in the figure and
the duct [B].
Sealant - General Electric: RTV100 (Black)
○Do not apply sealant to the inside [C] of the duct.
• Install the air cleaner housing [A] as shown in the figure.

Approximately 60° [B]
Inside [C]
• Tighten:
Torque - Air Cleaner Housing Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)
Air Cleaner Housing Dust and/or Water Inspection

• Refer to the Air Cleaner Housing Dust and/or Water In-
spection in the Periodic Maintenance chapter.
Fuel Tank
Fuel Tank Removal
WARNING
under certain conditions. Turn the main switch OFF.
Do not smoke. Make sure the area is well-ventilated
and free from any source of flame or sparks; this
includes any appliance with a pilot light.
• Remove:
Mounting Rivets [A]
Screws [B]
• Tilt up the seat [A].

• Remove:the fuel tank cap [B].
Remove
• Mounting Rivets [C]
Screws [D]
Fuel Tank Cover [E]
Front Seat Lower Cover [F]
• 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 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 ∼
•○Install the dampers on the collars, as shown.

Position the damper [A] so that its thicker side [B] faces
the front side.
○Position the dampers [C] so that its thicker side [D] faces
downward.
Front Side [E]
• Replace the nut [I] with a new one.
• Install:
Fuel Tank Mounting Bolts [F]
Washers [G]
Collars [H]
Nut
[I] KAF620M9 ∼ MC/N9/P9 ∼ PC
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.
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.
Fuel Tank Cleaning/Inspection

WARNING
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low flash-point solvents to clean the tank.
• Remove the fuel tank and drain it.

• Fuel Level Gauge (KAF620M9 ∼ MC/N9/P9 ∼ PC, see
Remove:
Fuel Level Gauge Removal)

Fuel Pump (see Fuel Pump Removal)
• 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.
Fuel Level Gauge Removal (KAF620M9 ∼

MC/N9/P9 ∼ PC)
WARNING
Fuel Tank

• Check
Pry off the gauge cap [A] and discard the cap.
• If the grooves
the grooves [B] in the fuel tank boss.
are damaged by removing the cap or can
not hold the cap nails, the fuel tank must be replaced.
• Pull out the fuel level gauge [C].
Fuel Level Gauge Installation (KAF620M9 ∼

MC/N9/P9 ∼ PC)
WARNING
• 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.
Evaporative Emission Control System (CAL Model and KAF620MB ∼/PB ∼)
The Evaporative Emission Control System routes fuel va-

pors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Al-
though no adjustments are required, a thorough visual in-
spection must be made at the intervals specified by the Pe-
riodic Maintenance Chart.
Parts Removal/Installation
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
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.
• To prevent the gasoline from flowing into or out of the

canister, hold the separator perpendicular to the ground.
• Connect the hoses according to the diagram of the sys-
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
Hose Inspection
• Refer to the Evaporative Emission Control System In-
spection (CAL Model and KAF620MB ∼/PB ∼) in the Pe-
Canister Inspection
• Refer to the Evaporative Emission Control System In-
spection (CAL Model and KAF620MB ∼/PB ∼) in the Pe-
Evaporative Emission Control System (CAL Model and KAF620MB ∼/PB ∼)
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
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.
S: Follow the specified tightening sequence.
4-4 COOLING SYSTEM
Specifications

Coolant
Type Permanent type of antifreeze – – –
(Soft water and ethylene glycol plus
corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Color Green – – –
Mixed Ratio Soft water 50%, coolant 50% – – –
Freezing Point –35°C (–31°F) – – –
Total Amount 4.3 L (4.5 US qt) – – –
Water Pump
Water Pump Shaft Diameter 9.975 ∼ 9.990 mm 9.94 mm
(0.3927 ∼ 0.3933 in.) (0.391 in.)
Water Pump Shaft Bearing Inside 10.020 ∼ 10.058 mm 10.09 mm
Diameter (0.3945 ∼ 0.3960 in.) (0.397 in.)
Radiator Cap
Relief Pressure 93 ∼ 123 kPa – – –
(0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
Thermostat
Valve Opening Temperature 81 ∼ 84°C (178 ∼ 183°F) – – –
Valve Full Opening Lift 8 mm (0.31 in.) or more at 95°C (203°F) – – –
COOLING SYSTEM 4-5
Sealant
Liquid Gasket, TB1211:
56019-120
4-6 COOLING SYSTEM
Coolant Flow Chart
COOLING SYSTEM 4-7
Coolant Flow Chart
1. Radiator
2. Radiator Fan
3. Radiator Cap
4. Reserve Tank
5. Water Pump
6. Cylinder
7. Thermostat
9. Air Bleeder Bolt (Water Pipe)
10. Air Bleeder Bolt (Inlet Manifold)
11. Cylinder Head
This engine is equipped with a highly efficient pressurized cooling system using a thermostat to
maintain an optimum operating temperature. Coolant bypasses the closed thermostat when cold until
operating temperature is attained, causing the engine to warm up more quickly. If the coolant temper-
ature becomes too high, the water temperature sensor on the engine activates the water temperature
warning indicator light to alert the operator or cooling problem.
4-8 COOLING SYSTEM
Coolant
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room of ambi-
ent temperature).
NOTICE
Do not check the level through the coolant filler by
removing the radiator cap. If the cap is removed,
the coolant will flow out from the reservoir tank.
• Open the front cargo hood.

• Check the coolant level in the reserve tank [A] with the
vehicle held perpendicularly.
If the coolant level is lower than the L (Low) [B] mark,
remove the reserve tank cap [C], then add coolant to the
F (Full) [D] mark.
NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine
parts. In an emergency, soft water can be added.
But the diluted coolant must be returned to the cor-
rect mixture ratio within a few days.
If coolant must be added often, or the reservoir tank
has run completely dry; there is probably leakage in
the cooling system. Check the system for leaks.
Coolant Draining
• Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Filling
• Refer to the Coolant Change in the Periodic Maintenance
chapter.
Coolant Reserve Tank Removal
• Quick Rivets [A]
Remove:

Partition [C]
COOLING SYSTEM 4-9
Coolant
• Remove the coolant reserve tank mounting bolts [A].

• Disconnect: cap and poor the coolant into a container.
Remove the
• Reserve Tank Overflow Hose [B]
• Remove:
Radiator Overflow Hose [C]
Coolant Reserve Tank
Coolant Reserve Tank Installation

•○Installation is the reverse of removal, note the following.
Insert the projection [A] of the coolant reserve tank into
the grommet [B] on the font cargo compartment.
○Run the hoses according to the Cable, Wire, and Hose
Routing section in the Appendix chapter.
○Fill the coolant reserve tank with coolant (see Coolant
Change in the Periodic Maintenance chapter).
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.
• Build up pressure in the system carefully until the pres-

sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
NOTICE
During pressure testing, do not exceed the pres-
sure for which the system is designed. The maxi-
mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
• Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is all right.
If the pressure drops soon, check for leaks.
4-10 COOLING SYSTEM
Water Pump
Water Pump Removal
•Maintenance
Drain the coolant (see Coolant Change in the Periodic
chapter).
• Torque Converter Case (see Torque Converter Case Re-
Remove:
moval in the Converter System chapter)

• Disconnect the water hoses [A].
• Remove:
Water Pump Cover Bolts [B]
Water Pump Cover [C]
• 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]
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 mechanical seal initial lubrica-
tion.
• Apply coolant to the surfaces of the rubber seal and seal-
ing seat [A], and press the rubber seal [B] and sealing
seat into the impeller by hand until the seat bottoms out.
• Fit the washer tab [A] to the notch [B] of the housing.
• the drive gear notches [C] to the pin [D].
Fit
• Install the new gaskets.

• Install the water pump housing turning the impeller so that
the drive gear [A] engages with the camshaft gear [B].
• Tighten the water pump cover bolts and housing bolt in

accordance with the order shown.
[1] M6, L = 45 mm (1.77 in.)
[2] M6, L = 65 mm (2.56 in.)
[3] M6, L = 45 mm (1.77 in.)
[4] M6, L = 75 mm (2.95 in.)
[5] M6, L = 45 mm (1.77 in.)
[6] M8, L = 70 mm (2.76 in.)
Torque - Water Pump Cover Bolts [1 ∼ 4] (M6): 8.8 N·m (0.90
kgf·m, 78 in·lb)
Water Pump Housing Bolt [5] (M6): 8.8 N·m (0.90
kgf·m, 78 in·lb)
Water Pump Cover Bolt [6] (M8): 25 N·m (2.5
kgf·m, 18 ft·lb)
4-12 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 passages. Re-
place the mechanical seal [A] or O-ring [B].
• Measure the diameter [A] of the water pump shaft.

If the shaft has worn past the service limit, replace the
shaft with a new one.
Water Pump Shaft Diameter
Standard: 9.975 ∼ 9.990 mm (0.3927 ∼ 0.3933 in.)
• 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.)
COOLING SYSTEM 4-13
Radiator and Radiator Fan
Radiator Removal
• Remove:
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
If any one of them shows visible damage, replace the cap.
• Install the cap [A] on a cooling system pressure tester [B].

NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leakage.
• Watching the pressure gauge, slowly pump the pressure

tester to build up the pressure. The gauge pointer must
remain within the relief pressure range in the table below
at least 6 seconds. Continue to pump the tester until the
relief valve opens, indicated by the gauge pointer flicks
downward. The relief valve must open within the specified
range.
Radiator Cap Relief Pressure
Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi) for 6 seconds
If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.
4-16 COOLING SYSTEM
Thermostat
Thermostat Removal
• Remove:
Hose [A]
• 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
• Replace the gasket with a new one.

• Coolant (see Coolant Change in the Periodic Mainte-
Adjust:
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
• To check valve opening temperature, suspend the ther-

mostat in a container of water and raise the temperature
of the water.
If the measurement is out of the specified range, replace
the thermostat.
Thermostat Valve Opening Temperature
Standard: 81 ∼ 84°C (178 ∼ 183°F)
○The thermostat [A] must be completely submerged and
must not touch the container sides or bottom. Suspend
an accurate thermometer [B] in the coolant so that the
sensitive portions [C] are located in almost in the same
depth. It must not touch the container, either.
4-18 COOLING SYSTEM
Hoses and Pipes
Hose and Pipe Installation
• Install the hoses and pipes being careful to follow bend-
ing direction or diameter. Avoid sharp bending, kinking,
flattening, or twisting.
•Install the clamps [A] as near as possible to the hose end
to clear the raised rib or the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to pre-
vent the clamps from contacting anything.
Hose Inspection
• 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
Water Temperature Sensor Inspection
• Refer to the Water Temperature Sensor Inspection in the
ENGINE TOP END 5-1
Engine Top End

Table of Contents
Exploded View........................................................................................................................ 5-2
Specifications ......................................................................................................................... 5-4
Special Tools .......................................................................................................................... 5-5
Cylinder Head ........................................................................................................................ 5-6
Cylinder Compression Measurement................................................................................ 5-6
Cylinder Head Removal .................................................................................................... 5-6
Cylinder Head Installation ................................................................................................. 5-8
Cylinder Head Disassembly and Assembly (Valve Mechanism Removal and
Installation)..................................................................................................................... 5-9
5
Cylinder Head Warp Inspection ........................................................................................ 5-9
Valves ..................................................................................................................................... 5-10
Valve Clearance Inspection .............................................................................................. 5-10
Valve Clearance Adjustment............................................................................................. 5-10
Valve Seat Inspection ....................................................................................................... 5-10
Valve Seat Repair ............................................................................................................. 5-11
Valve Spring Free Length Inspection ................................................................................ 5-14
Valve Head Thickness Inspection ..................................................................................... 5-14
Valve Stem Bend Inspection ............................................................................................. 5-14
Valve Stem Diameter Inspection....................................................................................... 5-14
Valve Guide Inside Diameter Inspection ........................................................................... 5-15
Measuring Valve/Valve Guide Clearance (Wobble Method) Inspection............................ 5-15
Rocker Arm/Shaft Wear Inspection................................................................................... 5-15
Rocker Arm Push Rod Inspection..................................................................................... 5-16
Exhaust Pipe and Muffler ....................................................................................................... 5-17
Exhaust Pipe Removal...................................................................................................... 5-17
Muffler Removal................................................................................................................ 5-17
Exhaust Pipe and Muffler Installation................................................................................ 5-17
Exhaust Pipe and Muffler Inspection ................................................................................ 5-18
Spark Arrester Cleaning.................................................................................................... 5-18
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
Torque
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.
M: Apply molybdenum disulfide grease.
5-4 ENGINE TOP END
Specifications

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.)
Valves
Valve Clearance (When cold) 0.25 mm (0.0098 in.) –––

Valve Seating Surface:
Outside Diameter:
Inlet 29.5 mm (1.16 in.) –––
Exhaust 25.5 mm (1.00 in.) –––
Width 0.5 ∼ 1.1 mm (0.02 ∼ 0.04 in.) –––
Valve Seat Cutting Angle 45° –––
Valve Spring Free Length 34.3 mm (1.35 in.) 32.6 mm (1.28 in.)
Valve Head Thickness 0.85 mm (0.033 in.) 0.4 mm (0.02 in.)
Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002 in.)
Valve Stem Diameter:
Inlet 5.960 ∼ 5.975 mm (0.2346 ∼ 0.2352 in.) 5.95 mm (0.2342 in.)
Exhaust 5.950 ∼ 5.965 mm (0.2342 ∼ 0.2348 in.) 5.94 mm (0.2338 in.)
Valve Guide Inside Diameter 6.000 ∼ 6.015 mm (0.2362 ∼ 0.2368 in.) 6.08 mm (0.239 in.)
Valve/Guide Clearance
(Wobble Method):
Inlet 0.06 ∼ 0.12 mm (0.0024 ∼ 0.0047 in.) 0.26 mm (0.010 in.)
Exhaust 0.08 ∼ 0.14 mm (0.0031 ∼ 0.0055 in.) 0.31 mm (0.012 in.)
Rocker Shaft Diameter 11.989 ∼ 12.000 mm 11.96 mm (0.4709 in.)
(0.47201 ∼ 0.47244 in.)
Rocker Arm Inside Diameter 12.006 ∼ 12.024 mm 12.06 mm (0.4748 in.)
(0.47268 ∼ 0.47338 in.)
Rocker Arm Push Rod Runout TIR 0.5 mm (0.02 in.) or less TIR 0.8 mm (0.03 in.)
ENGINE TOP END 5-5
Special Tools
Outside Circlip Pliers: Compression Gauge Adapter, M14 × 1.25:
57001-144 57001-1159
Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 30:

57001-221 57001-1187
Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 32° - 33:
57001-1116 57001-1199
Valve Seat Cutter, 32° - 30: Valve Seat Cutter Holder, 6:

57001-1120 57001-1360
Valve Seat Cutter Holder Bar:

57001-1128
5-6 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
• 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 running.
• Stop the engine, disconnect the spark plug cap, and re-
move the spark plug of the each cylinder.
• Attach a compression gauge adapter [A] and gauge [B]
firmly into the one spark plug hole.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M14 ×1.25:
57001-1159
• Using the starter motor, turn the engine over with the throt-
tle fully open until the compression gauge stops rising;
this is the highest compression reading obtainable.
Cylinder Compression
Usable Range: 1 000 ∼ 1 520 kPa (10.2 ∼ 15.5 kgf/cm²,
145 ∼ 220 psi) @490 r/min (rpm)
• Repeat the measurement to the other cylinder.

The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
Cylinder Carbon accumulation on piston and Remove the carbon deposits and
compression cylinder head, and in combustion replace damaged parts if necessary.
higher than usable chamber possibly due to damaged
range valve stem oil seal and/or damaged
piston oil rings
Incorrect cylinder head gasket Replace with a gasket of the proper
thickness thickness.
Cylinder Gas leakage around cylinder head Replace damaged gasket and check
compression lower cylinder head warp.
than usable range Bad condition of valve seating Repair if possible.
Incorrect valve, piston/cylinder Adjust.
clearance
Piston seizure Inspect cylinder and liner and
replace/repair as necessary.
Bad condition of piston ring and/or Replace.
piston ring grooves
Cylinder Head Removal

• Remove:
Inlet Manifold (see Throttle Body Assy Removal in the
Fuel System (DFI) chapter)
Alternator Cover (see Alternator Rotor and Stator Re-
ENGINE TOP END 5-7
Cylinder Head
For front cylinder
•Tilt up the seat.
•Remove the oil filler pipe bolts [A].
• Remove:
Spark Plug Cap [A]
Cylinder Head Cover Bolts [B]
Cylinder Head Cover [C]
For rear cylinder

•Remove:
Water Hose [A]
Spark Plug Cap [B]
Cylinder Head Cover Bolts [C]
Cylinder Head Cover [D]
• Turn the alternator rotor clockwise so that the mark "R"

[A] on the rotor aligns with the mark [B] on the crankcase
breather cover. Check the rocker arms are free. If not,
turn the rotor more one turn and free the rocker arms.
• 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.
• Turn the alternator rotor clockwise so that the mark "R"

[A] on the rotor aligns with the mark [B] on the crankcase
breather cover.
• Apply
rod.
engine oil to the both ends and shaft of the push
• Install the push rods in their original positions of the tappet

hollows [A]
• Check that inlet and exhaust push rods on each cylinder
are at lowest position on the cam lobes. If the piston is not
at the T.D.C of the compression stroke, turn the alternator
rotor clockwise one turn (360°) and reset each piston at
the T.D.C of the compression stroke.
• Be sure the end of the push rods are correctly seated on
the tappets.
• Assemble the cylinder head (see Cylinder Head Disas-

sembly and Assembly).
• Tighten the cylinder head bolts in the order shown.
Torque - Cylinder Head Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)
• Replace the gasket [A] with a new one.

• Install the cylinder head cover.
ENGINE TOP END 5-9
Cylinder Head
Cylinder Head Disassembly and Assembly
(Valve Mechanism Removal and Installation)
• Remove:
Cylinder Head (see Cylinder Head Removal)
Circlips [A]
Rocker Shaft [B]
Rocker Arms [C]
Special Tool - Outside Circlip Pliers: 57001-144
• 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.
• Check to see that the valve moves smoothly up and down

in the guide.
• Check to see that the valve seats properly in the valve
seat. If it does not, repair the valve seat.
Cylinder Head Warp Inspection
• Lay a straightedge [A] across the lower surface of the
head at several different points, and measure the warp by
inserting a thickness gauge [B] between the straightedge
and the head.
If warp exceeds the service limit, repair the mating sur-
face. Replace the cylinder head if the mating surface is
badly damaged.
Cylinder Head Warp
5-10 ENGINE TOP END
Valves
Valve Clearance Inspection
• Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter
Valve Clearance Adjustment
• Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter
Valve Seat Inspection
• Remove the valve.
• and valve seat
Check the valve seating surface [A] between the valve [B]
[C].
• Push the valve into the
Coat the valve seat with machinist’s dye.
• Rotate the valve againstguide.
• Pull the valve out, and check
the seat with a lapping tool.
• valve head. It must be the correct
the seating pattern on the
width and even all the
way around.
NOTE
○The valve stem and guide must be in good condition, or
this check will not be valid.
If the valve seating pattern is not correct, repair the seat.
• Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter of the valve seating pattern is too
large or too small, repair the seat.
Valve Seating Surface Outside Diameter
Inlet: 29.5 mm (1.16 in.)
Exhaust: 25.5 mm (1.00 in.)
• Measure the seat width [E] of the portion where there is

no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
Too Wide [G]
Too Narrow [H]
Uneven [J]
If the width is too wide, too narrow or uneven, repair the
seat (See Valve Seat Repair).
Valve Seating Surface Width
Standard: 0.5 ∼ 1.1 mm (0.02 ∼ 0.04 in.)
ENGINE TOP END 5-11
Valves
Valve Seat Repair
• Follow the manufacturer’s instructions for use of valve
seat cutters.
Special Tools - Valve Seat Cutter Holder, 6: 57001-1360
Valve Seat Cutter Holder Bar: 57001-1128
[For Inlet Valve Seat]

Valve Seat Cutter, 45° - 35: 57001-1116
[For Exhaust Valve Seat]
If the manufacture’s instructions are not available, use the
following procedure.
Seat Cutter Operating Cares
1. The valve seat cutter [A] is designed only for valve seat
repair. Therefore the cutter must not be used for other
purposes.
2. Do not drop or hit the valve seat cutter, or the diamond
particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
Special Tools - Valve Seat Cutter Holder, 6: 57001-1360
[B]
Valve Seat Cutter Holder Bar: 57001-1128
[C]
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.
• Measure the outside diameter (O.D.) of the seating sur-

face with a vernier caliper.
If the O.D. of the seating surface is too small, repeat the
45° grind until the diameter is within the specified range.
If the O.D. of the seating surface is too large, make the
32° grind described below.
•Grind the seat at a 32° angle until the seat O.D. is within
the specified range.
○To make the 32° grind, fit a 32° cutter to the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat O.D. mea-
surement step above.
• 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
Valve Head Thickness Inspection

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

• Place the valve in V blocks at each end of the stem, and
set a dial gauge [A] on the stem at a point halfway be-
tween the blocks. Turn the valve to measure the bend.
The difference between the highest and the lowest dial
readings is the amount of bend.
If the valve stem bend is greater than the service limit,
Valve Stem Bend
Standard: TIR 0.01 mm (0.0004 in.) or less
Service Limit: TIR 0.05 mm (0.002 in.)
Valve Stem Diameter Inspection

• Measure the diameter of the valve stem [A] in two di-
rections at right angles, at four different positions on the
stem.
If any single measurement is less than the service limit,
Valve Stem Diameter
Standard:
Inlet 5.960 ∼ 5.975 mm (0.2346 ∼ 0.2352 in.)
Exhaust 5.950 ∼ 5.965 mm (0.2342 ∼ 0.2348 in.)
Service Limit
Inlet 5.95 mm (0.2342 in.)
Exhaust 5.94 mm (0.2338 in.)
ENGINE TOP END 5-15
Valves
Valve Guide Inside Diameter Inspection
• Measure the inside diameter [A] of the valve guide.
If the valve guide has worn past the service limit, replace
the cylinder head.
Valve Guide Inside Diameter
Standard: 6.000 ∼ 6.015 mm (0.2362 ∼ 0.2368 in.)
Measuring Valve/Valve Guide Clearance (Wobble

Method) Inspection
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve/valve guide clearance
with the wobble method, as indicated below.
• Insert a new valve [A] into the guide [B] from the top of
the head.
• Set a dial gauge against the stem perpendicular to it as
close as possible to the cylinder head upper surface.
• Move the stem back and forth [C] to measure valve/guide
clearance.
• Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the cylin-
der head.
NOTE
○The reading is not actual valve/guide clearance be-
cause the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)

Standard:
Inlet 0.06 ∼ 0.12 mm (0.0024 ∼ 0.0047 in.)
Exhaust 0.08 ∼ 0.14 mm (0.0031 ∼ 0.0055 in.)
Service Limit:
Inlet 0.26 mm (0.010 in.)
Exhaust 0.31 mm (0.012 in.)
Rocker Arm/Shaft Wear Inspection

• Measure the diameter [A] of the rocker shaft.
If the shaft has worn past the service limit, replace the
rocker shaft with a new one.
Rocker Shaft Diameter
Standard: 11.989 ∼ 12.000 mm (0.47201 ∼ 0.47244
in.)
5-16 ENGINE TOP END
Valves
• Measure the inside diameter [A] of the rocker arm.

rocker arm with a new one.
Rocker Arm Inside Diameter
12.006 ∼ 12.024 mm (0.47268 ∼ 0.47338
Standard:
in.)
Rocker Arm Push Rod Inspection

• Place the rocker arm push rod in V blocks that are as
far apart as possible, and set a dial gauge [A] on the rod
at a point halfway between the blocks. Turn the rod to
measure the runout. The difference between the highest
and the lowest dial readings is the amount of runout.
If the runout exceeds the service limit, replace the rod.
Rocker Arm Push Rod Runout
Standard: TIR 0.5 mm (0.02 in.) or less
ENGINE TOP END 5-17
Exhaust Pipe and Muffler
Exhaust Pipe Removal
• Remove:
Exhaust Pipe Cover Bolts [A]
Exhaust Pipe Cover [B]
• 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]
Exhaust Pipe and Muffler Installation

• Apply a non-permanent
mounting bolts.
locking agent to the muffler
• 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
Exploded View
Torque
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
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
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
Specifications

Drive Belt
Belt Deflection 28 ∼ 33 mm (1.1 ∼ 1.3 in.) 45 mm (1.8 in.)
Belt Width 30.3 mm (1.19 in.) 28.8 mm (1.13 in.)
Drive Pulley
Spider Wear Guide Clearance 0 ∼ 0.40 mm (0 ∼ 0.016 in.) – – –
Cover Bushing Inside Diameter 28.075 ∼ 28.175 mm (1.105 ∼ 1.109 in.) 28.21 mm (1.111 in.)
Sheave Bushing Inside Diameter 38.075 ∼ 38.175 mm (1.499 ∼ 1.503 in.) 38.21 mm (1.504 in.)
Spider Wear Guide Thickness 7.3 ∼ 7.7 mm (0.287 ∼ 0.303 in.) – – –
Spring Free Length 73.6 mm (2.90 in.) – – –
Driven Pulley
Sheave Bushing Inside Diameter 38.075 ∼ 38.175 mm (1.499 ∼ 1.503 in.) 38.21 mm (1.504 in.)
Wear Shoe Width ––– 16.3 mm (0.64 in.)
Spring Free Length 112.6 mm (4.43 in.) – – –
Special Tools
Outside Circlip Pliers: Driven Pulley Holder:
57001-144 57001-1465
Drive Pulley Wrench: Pulley Holder Attachment:

57001-1411 57001-1472
Drive & Driven Pulley Holder: Drive Pulley Holder:

57001-1412 57001-1548
Drive Pulley Puller Bolt: Flywheel & Pulley Holder:

57001-1429 57001-1605
Air Cleaner
Air Cleaner Housing Removal
• Loosen:
Clamps [A]
• Air Ducts [B]
Remove:
[C] KAF620M9/N9/P9 and KAF620MA/PA early models

[D] KAF620MA/PA late models and KAF620MB ∼/PB ∼
• 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 ∼
• After removing the housing, stuff pieces of lint-free, clean

cloth into the torque converter cover duct to keep dirt out
of the torque converter.
NOTICE
If dirt gets into the torque converter, excessive wear
and loss of driving power may result.
Air Cleaner
Air Cleaner Housing Installation
• When installing the dampers [A], position the thicker side
[B] to upper side [C].
• Install:
Air Cleaner Housing [D]
Collars [E]
Air Cleaner Housing Bolts [F], Washers [G] and Nuts [H]
For KAF620M9/N9/P9 and KAF620MA/PA Early Models
•Tighten:
ft·lb)
For KAF620MA/PA Late Models and KAF620MB ∼/PB ∼
•Tighten:
ft·lb)
• Install:
Air Ducts [I]
• of ducts.the clamps [J] at 3 mm (0.12 in.) [K] from the end
Tighten
• Tighten
duct.
the clamp [L] to the bare position from the end of
Air Cleaner
Air Cleaner Element Removal
For KAF620M9/N9/P9 and KAF620MA/PA Early Models
•Remove:
Wingbolts [A]
Cap [B]
For KAF620MA/PA Late Models and KAF620MB ∼/PB ∼

•Remove:
Clamps [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.
Air Cleaner Element Cleaning/Inspection

• Refer to the Air Cleaner Element Cleaning/Inspection in
the Periodic Maintenance chapter.
Torque Converter
Torque Converter Cover Removal
• Remove:
Left Rear Shock Absorber (see Rear Shock Absorber
Removal in the Suspension chapter)
Air Cleaner Housing for Torque Converter (see Air
Cleaner Housing Removal)
Exhaust Pipes (see Exhaust Pipe Removal in the Engine
Top End chapter)
• Loosen:
Clamp Screw [A]
• Remove:
Air Duct [B]
• Remove:
Converter Cover Bolts
Heat Guard Plate [A]
• Remove:
Torque Converter Cover [A]
Torque Converter Cover Installation

• Installation is basically the reverse of removal.
• Tighten:
NOTE
○This vehicle is equipped with one of the two types of
converter covers.
○One has collars [A] embedded in the mounting holes of
the cover and the other has no collars.
Torque - Converter Cover Bolts (Converter Cover without
Collars): 7.0 N·m (0.71 kgf·m, 62 in·lb)
Converter Cover Bolts (Converter Cover with Col-
lars): 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Install the air duct [A] so that the white paint mark of the
duct fits into this position [B].
• Tighten the clamp screw [C].
Torque Converter
Torque Converter Case Removal

• Remove:
Drive Pulley (see Drive Pulley Removal)
Driven Pulley (see Driven Pulley Removal)
Torque Converter Case Bolts [A] and Washers
Torque Converter Case [B]
Torque Converter Case Installation

• Confirm:
O-ring [A]
Engine Positioning Plate [B] (see Engine Installation in
the Engine Removal/Installation chapter)
Torque Converter
• 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)
Torque Converter Case Disassembly

• Remove:
Torque Converter Case (see Torque Converter Case Re-
moval)
Collars [A] and Dampers
Grommet [B]
• Remove:
Screws [A]
Heat Guard Plate [B]
Torque Converter Case Assembly

• Install:
Heat Guard Plate [A]
Screws [B]
Grommet [C]
Collars [D] and Dampers [E]
Drive Belt
Drive Belt Removal
• Remove the drive pulley [A] (see Drive Pulley Removal).
NOTE
○Before removing, observe the direction the belt’s printed
information [B] (such as manufacturer’s name) is facing
so that it may be reinstalled on the pulleys to rotate in
the same direction as originally installed.
• Lift the drive belt off the driven pulley [C].

Drive Belt Installation
NOTE
○Be sure the printed information faces the same direc-
tion so the belt rotates in the same direction as origi-
nally installed. When installing a new belt, install it so
the printed information [A] can be read from beside the
vehicle.
• Installation is basically the reverse of removal.

• Install the drive[B]pulley
Loop the belt over the drive and driven pulleys.
• (see Drive Pulley Installation).
• Put the transmission in neutral, and rotate the driven pul-

ley to allow the belt to return to the top [A] of the sheaves,
before measuring belt deflection.
Drive Belt Inspection

• Refer to the Drive Belt Inspection in the Periodic Mainte-
nance chapter.
Drive Belt Deflection Inspection
• Refer to the Drive Belt Deflection Inspection in the Peri-
odic Maintenance chapter.
Drive Belt Deflection Adjustment
• Refer to the Drive Belt Deflection Adjustment in the Peri-
Drive Pulley
Drive Pulley Removal
• Remove:
Torque Converter Cover (see Torque Converter Cover
Removal)
Cooling Fan Cover Bolts [A]
Cooling Fan Cover [B]
• Install the drive pulley holder [A] as shown in the figure.

Special Tool - Drive Pulley Holder: 57001-1548
• Remove the drive pulley bolt [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
Drive Pulley Disassembly

• Hold the drive pulley with the drive & driven pulley holder
[A] in a vise.
Special Tool - Drive & Driven Pulley Holder: 57001-1412
○Mount the pulley holder base plate chamfered side up in
a vise, with the short guide (L = 41 mm) (1.614 in.) and
short stoppers (L = 16 mm) (0.630 in.) installed.
• Remove:
Drive Pulley Cover Bolts [B]
Drive Pulley Cover [C]
• Remove:
Spring [A]
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]
Drive Pulley Assembly

• Install the ramp weight [A] as shown.
• Replace the ramp weight nuts [B] with new ones.
• Tighten:
Torque - Ramp Weight Nuts: 6.9 N·m (0.70 kgf·m, 61 in·lb)
• Check the ramp weights swing smoothly.
• 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.
Drive Pulley
○Hold the fixed sheave [A] with the drive & driven pulley
holder [B] in a vise.
• Clean the threads of the fixed sheave and spider.

• Movable Sheave [A]
Install:
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.
• Fit the spacer [A] in the spider recess [B].
• Tighten:
Special Tool - Drive Pulley Wrench [A]: 57001-1411
Torque - Spider: 275 N·m (28.0 kgf·m, 203 ft·lb)
• Put the spring [A] in the groove of the spider.

• Tighten:
Align the arrows [B] on the drive pulley cover and spider.
•
Torque - Drive Pulley Cover Bolts: 12.5 N·m (1.3 kgf·m, 111
in·lb)
Drive Pulley
Spider/Wear Guide Clearance Inspection
• Remove:
Drive Pulley Cover and Spring (see Drive Pulley Disas-
sembly)
Special Tool - Drive & Driven Pulley Holder: 57001-1412
• Set the drive pulley without the spring onto the pulley
holder.
• Temporarily
sheave.
install the drive pulley cover on the movable
• Turn the spider clockwise and hold it there

• [A] and thethepost
Measure resulting clearance between the wear guide
[B] on the movable sheave at three posi-
tions as shown.
Spider/Wear Guide Clearance
Standard: up to 0.40 mm (0.016 in.), and there must
be kept a clearance which the movable
sheave [C] moves smoothly until it
touches the fixed sheave [D] with its own
weight or load under 10 N (1.0 kgf).
If any of the measurements are not the specified range,
replace all wear guides.
Drive Pulley Inspection

If the sheave surfaces [A] appear damaged, replace the
sheaves.
• Replace any sheave which has uneven wear on the belt

contacting surface.
[A] Sheave Surface
[B] Straight Edge
Drive Pulley
If the guide bushings are damaged or worn, replace them.
Cover Bushing Inside Diameter [A]
Standard: 28.075 ∼ 28.175 mm (1.105 ∼ 1.109 in.)
Sheave Bushing Inside Diameter [B]

Standard: 38.075 ∼ 38.175 mm (1.499 ∼ 1.503 in.)
If the wear guides [A] are damaged or worn, replace them.

Spider Wear Guide Thickness [B]
Standard: 7.3 ∼ 7.7 mm (0.287 ∼ 0.303 in.)
• Check the spider/wear guide clearance (see Spider/Wear

Guide Clearance Inspection).
If the ramp weights [A] are damaged or worn, replace

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

If the pins [B] are damaged or worn, replace them.
If the washers [C] are damaged or worn, replace them.
If the spring is damaged, replace the spring.

Spring Free Length [A]
Drive Pulley
Bushing Installation
• Press the cover bushing [A] into the cover [B] so that the
bushing end is flush with the boss [C] of the cover.
• Press the sheave bushing [A] into the movable sheave

[B] so that the bushing end is flush with the end [C] of the
sheave.
Drive Pulley Installation

• Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.
Fixed Sheave Tapered Portion [A]
Crankshaft Tapered Portion [B]
WARNING
These cleaning fluids are usually highly flammable
and harmful if breathed for prolonged periods. Be
sure to heed the fluid manufacturer’s warnings.
• Replace the drive pulley bolt [A] with a new one.

• drive pulleywashers
Install the [B] and stepped washer [C] on the
bolt as shown.
• 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)
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)
Driven Pulley
Driven Pulley Removal
• Remove:
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.
• Turn the flange nut [A] counterclockwise slowly and re-

move the nut and adapter [B].
Driven Pulley
• 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]
Driven Pulley Assembly

• Install
shown.
the wear shoe [A] on the movable sheave [B] as
• 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.
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.
•○Install the ramp [A] on the fixed sheave shaft.

Insert the spring end [B] into the hole “1”.
○Fit the flat portions [C] of the ramp and shaft splines.
○Put the spacer [A] and circlip [B] on the ramp.

○Install the adapter [C] and tighten the flange nut until the
ramp halfway, turn the movable sheave counterclockwise
120° and hold it.
○Push down the ramp until it is bottomed, and install the
spacer and circlip.
• Put back movable sheave slowly.
Driven Pulley Inspection
If the sheave surfaces [A] appear damaged, replace the
sheaves.
• Replace any sheave which has uneven wear on the belt
contacting surface.
[B] Straight Edge
If the guide bushings [A] are damaged or worn, replace

them.
Sheave Bushing Inside Diameter
Standard: 38.075 ∼ 38.175 mm (1.499 ∼ 1.503 in.)
Driven Pulley
If the splines [A] are damaged or worn, replace them.
If the spring is damaged, replace the spring.

Spring Free Length [A]
If the tabs on the spring are misaligned or the spring coils
are distorted, replace the spring.
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.
Driven Pulley Installation

• Install:
Driven Pulley
NOTE
○When engaging the spline on the driven pulley with the
spline on the shaft, do not damage the pulley’s spline.

Driven Pulley Bolt [A]
• Using the flywheel & pulley holder [B] and attachments
[C], tighten the driven pulley bolt.
Special Tools - Flywheel & Pulley Holder: 57001-1605
Pulley Holder Attachment: 57001-1472
Torque - Driven Pulley Bolt: 93 N·m (9.5 kgf·m, 69 ft·lb)
ENGINE LUBRICATION SYSTEM 7-1

Table of Contents
Exploded View........................................................................................................................ 7-2
Specifications ......................................................................................................................... 7-4
Sealant ................................................................................................................................... 7-5
Engine Oil Flow Chart............................................................................................................. 7-6
Engine Oil and Oil Filter.......................................................................................................... 7-7
Oil Level Inspection........................................................................................................... 7-7
Engine Oil Change............................................................................................................ 7-8
Oil Filter Removal ............................................................................................................. 7-8
Oil Filter Installation .......................................................................................................... 7-8
Oil Pump and Relief Valve...................................................................................................... 7-9
Oil Pump and Relief Valve Removal ................................................................................. 7-9
Oil Pump and Relief Valve Installation .............................................................................. 7-9
Oil Pump and Relief Valve Inspection............................................................................... 7-9 7
Oil Screen............................................................................................................................... 7-11
Oil Screen Removal .......................................................................................................... 7-11
Oil Screen Installation ....................................................................................................... 7-11
Oil Screen Cleaning/Inspection......................................................................................... 7-11
Oil Pressure Switch ................................................................................................................ 7-12
Oil Pressure Switch Removal ........................................................................................... 7-12
Oil Pressure Switch Installation ........................................................................................ 7-12
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
Exploded View
Torque
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
9. KAF620M9 ∼ MB/N9/P9 ∼ PB
10. KAF620M9 ∼ MD/N9/P9 ∼ PD
G: Apply grease.
SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).
Specifications

Engine Oil and Oil Filter
Engine oil:
Type API SG, SH, SJ, SL or SM with JASO MA,
– – –
MA1 or MA2
Viscosity SAE 10W-40 – – –
Capacity 1.3 L (1.4 US qt) (when filter is not removed) – – –
1.5 L (1.6 US qt) (when filter is removed) – – –
1.8 L (1.9 US qt) (when engine is completely – – –
dry)
Oil level Between F and L lines on dipstick – – –
Oil Pump and Relief Valve
Inner Rotor/Outer Rotor Less than 0.14 mm (0.0056 in.) 0.3 mm (0.01 in.)
Clearance
Inner Rotor Shaft Diameter 10.973 ∼ 10.984 mm (0.4320 ∼ 0.4324 in.) 10.923 mm (0.4300 in.)
Outer Rotor Diameter 40.53 ∼ 40.56 mm (1.596 ∼ 1.597 in.) 40.47 mm (1.593 in.)
Outer Rotor Width 9.95 ∼ 10.00 mm (0.392 ∼ 0.394 in.) 9.83 mm (0.387 in.)
Inner Rotor Shaft Bearing 11.000 ∼ 11.011 mm (0.4331 ∼ 0.4335 in.) 11.072 mm (0.4359 in.)
Inside Diameter
Outer Rotor Housing 40.680 ∼ 40.701 mm (1.6016 ∼ 1.6024 in.) 40.801 mm (1.6063 in.)
Inside Diameter
Rotor Housing Depth 10.03 ∼ 10.08 mm (0.395 ∼ 0.397 in.) 10.23 mm (0.403 in.)
Sealant
Liquid Gasket, TB1211:
56019-120
Engine Oil Flow Chart
1. Oil Screen
2. Oil Pump
3. Relief Valve
4. Oil Filter
5. Oil Pressure Switch
6. Crankshaft
7. Camshaft
8. Rocker Arm
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
Oil Level Inspection

NOTE
○If the vehicle has just been used, wait several minutes
for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
• Park the vehicle on level ground.

• Pull outthe
Tilt up seat.
• the dipstick [A] out of the dipstick tube, wipe it dry.
• Apply engine oil to the rubber seal lip [A] on the dipstick.
• 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.
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]
Oil Pump and Relief Valve Installation

NOTICE
Do not allow any dust or other foreign matter to en-
ter the oil pump.
• 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.
• Visually
[B].
inspect the relief valve spring [A], and steel ball
If any rough spots are found during the above inspection,

wash the valve clean with a high flash-point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
burns. Clean the parts in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working areas. Do not use gasoline or low
flash-point solvents to clean parts.
If cleaning does not solve the problem, replace the relief
valve parts.
• Measure the clearance between the high point of the inner

rotor and the high point of the outer rotor.
If the clearance exceeds the service limit, replace the in-
ner and outer rotors as a set.
Inner Rotor/Outer Rotor Clearance
Standard: Less than 0.14 mm (0.0056 in.)
• 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.)
Outer Rotor Diameter [B]

Standard: 40.53 ∼ 40.56 mm (1.596 ∼ 1.597 in.)
Outer Rotor Width [C]

Standard: 9.95 ∼ 10.00 mm (0.392 ∼ 0.394 in.)
Inner Rotor Shaft Bearing Inside Diameter [A]

Standard: 11.000 ∼ 11.011 mm (0.4331 ∼ 0.4335 in.)
Outer Rotor Housing Inside Diameter [B]

Standard: 40.680 ∼ 40.701 mm (1.6016 ∼ 1.6024 in.)
Rotor Housing Depth [C]

Standard: 10.03 ∼ 10.08 mm (0.395 ∼ 0.397 in.)
Oil Screen
Oil Screen Removal
• Remove:
Crankcase Cover (see Crankcase Cover Removal in the
Engine Bottom End chapter)
Oil Screen Cover Screws [A]
Oil Screen Cover [B]
• Remove:
Oil Screen [A]
Oil Screen Installation

• Clean the oil screen thoroughly whenever it is removed
(see Oil Screen Cleaning/Inspection).
• Install the oil screen in a original position.
• curely. the oil screen cover, and tighten the screws se-
Install
Oil Screen Cleaning/Inspection

• Clean the oil screen [A] with high flash-point solvent and
remove any particles stuck to it.
WARNING
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
• Check the screen carefully for any damage:

broken wire.
holes and
If the screen is damaged, replace it.

Oil Pressure Switch
Oil Pressure Switch Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Slide the switch cover [A].
• Switch Lead Terminal [B]
Remove:
Oil Pressure Switch [C]
Oil Pressure Switch Installation

• Apply silicone sealant to the threads of the oil pressure
switch and tighten it.
Torque - Oil Pressure Switch: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Connect the lead to the oil pressure switch.
• rosion. coat of grease on the terminal to prevent cor-
Put a light
• Install the switch cover [A] securely.

ENGINE REMOVAL/INSTALLATION 8-1
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
Exploded View
Torque
N·m kgf·m ft·lb
1 Engine Mounting Bolts 44 4.5 32
2 Engine Positioning Plate Bolts 20 2.0 15
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)
Inlet Manifold (see Throttle Body Assy Removal in the
Fuel System (DFI) chapter)
• Remove:
Oil Filler Pipe Bolts [A]
• Loosen the clamp screw [A].

• Oil Filler Pipe [B]
Remove:
• Disconnect:
Crankshaft Sensor Lead Connector [A]
Alternator Lead Connector [B]
Ignition Coil Lead/Oil Pressure Switch Lead/Starter Mo-
tor Lead Connector [C]
• 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
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
Engine Bottom End

Table of Contents
Exploded View........................................................................................................................ 9-2
Specifications ......................................................................................................................... 9-4
Special Tools .......................................................................................................................... 9-5
Crankcase Cover.................................................................................................................... 9-6
Crankcase Cover Removal ............................................................................................... 9-6
Crankcase Cover Installation ............................................................................................ 9-6
Camshaft and Tappets............................................................................................................ 9-7
Camshaft Removal ........................................................................................................... 9-7
Camshaft Installation ........................................................................................................ 9-7
Camshaft Inspection ......................................................................................................... 9-7
Cam Wear Inspection ....................................................................................................... 9-7
Camshaft Bearing/Journal Wear Inspection ..................................................................... 9-7
Cylinders and Pistons............................................................................................................. 9-9
Piston Removal ................................................................................................................ 9-9
Piston Installation.............................................................................................................. 9-10
Piston Ring, Piston Ring Groove Wear Inspection ........................................................... 9-12
Piston Ring End Gap Inspection ....................................................................................... 9-12 9
Cylinder Inside Diameter Inspection ................................................................................. 9-12
Piston Diameter Inspection ............................................................................................... 9-12
Boring, Honing .................................................................................................................. 9-13
Crankshaft and Connecting Rods........................................................................................... 9-14
Connecting Rod Removal ................................................................................................. 9-14
Connecting Rod Installation .............................................................................................. 9-14
Crankshaft Removal ......................................................................................................... 9-14
Crankshaft Installation ...................................................................................................... 9-14
Crankshaft Cleaning ......................................................................................................... 9-14
Connecting Rod Bend/Twist Inspection ............................................................................ 9-15
Connecting Rod Big End Side Clearance Inspection........................................................ 9-15
Connecting Rod Big End Bearing/Crankpin Wear Inspection........................................... 9-16
Crankshaft Runout Inspection........................................................................................... 9-17
Crankshaft Main Bearing/Journal Wear Inspection........................................................... 9-17
Breather Valve ........................................................................................................................ 9-19
Breather Valve Removal ................................................................................................... 9-19
Breather Valve Installation ................................................................................................ 9-19
Breather Valve Inspection ................................................................................................. 9-19
9-2 ENGINE BOTTOM END
Exploded View
Exploded View
Torque
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
6. KAF620M9 ∼ MB/N9/P9 ∼ PB
7. KAF620M9 ∼ MD/N9/P9 ∼ PD
G: Apply grease.
Specifications

Camshaft and Tappets
Cam Height: 25.735 ∼ 25.793 mm (1.0132 ∼ 1.0155 in.) 25.64 mm (1.0094 in.)
Camshaft Journal Diameter 15.957 ∼ 15.975 mm (0.6282 ∼ 0.6289 in.) 15.93 mm (0.627 in.)
Camshaft Bearing Inside 16.000 ∼ 16.018 mm (0.6299 ∼ 0.6306 in.) 16.08 mm (0.633 in.)
Diameter
Cylinders and Pistons
Piston Ring/Groove
Clearance:
Top 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.) 0.18 mm (0.0071 in.)
Second 0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.) 0.17 mm (0.0067 in.)
Piston Ring End Gap:
Top, Second 0.20 ∼ 0.40 mm (0.0079 ∼ 0.0157 in.) 0.7 mm (0.028 in.)
Cylinder Inside Diameter 75.980 ∼ 76.000 mm (2.9913 ∼ 2.9921 in.) 76.10 mm (2.996 in.)
Piston Diameter 75.935 ∼ 75.950 mm (2.9896 ∼ 2.9902 in.) 75.79 mm (2.984 in.)
Oversize Piston And Rings + 0.50 mm (0.020 in.) – – –
Piston Ring Groove Width:
Top 1.23 ∼ 1.25 mm (0.0484 ∼ 0.0492 in.) 1.33 mm (0.0524 in.)
Second 1.22 ∼ 1.24 mm (0.0480 ∼ 0.0488 in.) 1.32 mm (0.0520 in.)
Oil 3.01 ∼ 3.03 mm (0.1185 ∼ 0.1193 in.) 3.11 mm (0.1224 in.)
Piston Ring Thickness:
Top, Second 1.17 ∼ 1.19 mm (0.0461 ∼ 0.0469 in.) 1.1 mm (0.043 in.)
Piston/Cylinder Clearance 0.030 ∼ 0.065 mm (0.0012 ∼ 0.0026 in.) – – –
Crankshaft and Connecting
Rods
Connecting Rod Bend ––– TIR 0.15 mm (0.0059
in.)
Connecting Rod Twist ––– TIR 0.15 mm (0.0059
in.)
Connecting Rod Big End Side 0.3 ∼ 1.1 mm (0.012 ∼ 0.043 in.) 1.3 mm (0.051 in.)
Clearance
Connecting Rod Big End 0.024 ∼ 0.048 mm (0.0009 ∼ 0.0019 in.) 0.09 mm (0.0035 in.)
Bearing/Crankpin Clearance
Crankpin Diameter 33.967 ∼ 33.980 mm (1.3373 ∼ 1.3378 in.) 33.95 mm (1.337 in.)
Connecting Rod Big End 34.004 ∼ 34.015 mm (1.3387 ∼ 1.3392 in.) 34.04 mm (1.340 in.)
Inside Diameter
Crankshaft Runout Less than TIR 0.02 mm (0.0008 in.) TIR 0.05 mm (0.0020
in.)
Crankshaft Main Journal
33.959 ∼ 33.975 mm (1.3370 ∼ 1.3376 in.) 33.94 mm (1.336 in.)
Diameter
Crankshaft Main Bearing
Inside Diameter
on Crankcase (Bushing) 33.997 ∼ 34.064 mm (1.3385 ∼ 1.3411 in.) 34.12 mm (1.343 in.)
on Crankcase Cover 34.025 ∼ 34.041 mm (1.3396 ∼ 1.3402 in.) 34.10 mm (1.343 in.)
Special Tools
Piston Pin Puller Assembly:
57001-910
Piston Ring Compressor Grip:

57001-1095
Piston Ring Compressor Belt, 67 ∼ 79:

57001-1097
Crankcase Cover
Crankcase Cover Removal
• Remove:
Engine (see Engine Removal in the Engine Removal/In-
stallation chapter)
Water Pump (see Water Pump Removal in the Cooling
System chapter)
Crankcase Cover Bolts [A]
Crankcase Cover [B]
NOTE
○If the crankcase cover sticks, tap lightly with a mallet on
the alternator side near the knock pins.
Crankcase Cover Installation
• Be sure to replace the oil seal removed with a new one.
Press in the new oil seal using a press and suitable tools
so that the seal surface is flush with the surface of the
crankcase cover.
• Check to see that the crankcase knock pins [A] and O
-rings [B] are in place on the crankcase. If any of them
has been removed, replace it with a new one.

Crankshaft
Camshaft
• Grease:
Oil Seal Lips
• Install the crankcase cover so that the oil pump gear [A]
is engaged with the crankshaft gear.
• Tighten:
Torque - Crankcase Cover Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)

Engine Oil Dipstick Tube O-ring [A]
• Check to see the crankshaft turns freely.
Camshaft Removal
• Remove:
stallation chapter)
Cylinder Heads (see Cylinder Head Removal in the En-
gine Top End chapter)
Crankcase Cover (see Crankcase Cover Removal)
Camshaft [A]
Tappets [B]
○Turn the engine upside down to keep the tappets from
catching the cam lobes.
Camshaft Installation
Tappets
Camshaft Journals
Cam Surfaces
• Align the timing marks [A] on the camshaft and crankshaft
gears.
Camshaft Inspection
• Check the camshaft gear [A] for worn or broken teeth.
If excessively worn or broken teeth are observed, replace
the camshaft.
Cam Wear Inspection

• Measure the cam height [A] of each cam.
If any cam has worn past the service limit, replace the
camshaft.
Cam Height
Standard: 25.735 ∼ 25.793 mm (1.0132 ∼ 1.0155 in.)
Camshaft Bearing/Journal Wear Inspection

• Measure the diameter [A] of the camshaft journals.
If any journal has worn past the service limit, replace the
camshaft with a new one.
Camshaft Journal Diameter
Standard: 15.957 ∼ 15.975 mm (0.6282 ∼ 0.6289 in.)
• Measure the inside diameter [A] of the camshaft bearings.

If any bearing has worn past the service limit, replace the
crankcase and/or crankcase cover with a new one.
Camshaft Bearing Inside Diameter
Standard: 16.000 ∼ 16.018 mm (0.6299 ∼ 0.6306 in.)
Piston Removal
• Remove:
stallation chapter)
Cylinder Heads (see Cylinder Head Removal in the En-
Camshaft (see Camshaft Removal)
• Turn the crankshaft to expose the two connecting rod big
end cap bolts.
• Remove:
Connecting Rod Big End Cap Bolts [A]
Connecting Rod Big End Caps [B]
• 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
• Carefully spread the ring opening with your thumbs and

then push up on the opposite side of the ring [A] to remove
it.
• Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
Piston Pin
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]
• Position each piston ring end gap as shown.

[A] Arrow
[B] Top Ring End Gap, Upper Side Rail End Gap
[C] 45°
[D] Second Ring End Gap, Lower Side Rail End Gap
•○Assemble the pistons onto the connecting rods as shown.

No. 1 cylinder piston, align the arrow on the top of the
piston with "MADE IN JAPAN" on the connecting rod.
○No. 2 cylinder piston, align the arrow on the top of the
piston with opposite "MADE IN JAPAN" on the connecting
rod.
[A] No.1 Cylinder Piston
[B] No.2 Cylinder Piston
[C] Arrow
[D] “MADE IN JAPAN”
• 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)
Piston Ring, Piston Ring Groove Wear Inspection
• Check
ing.
for uneven groove wear by inspecting the ring seat-
The rings should fit perfectly parallel to the groove sur-

faces. If not, the piston must be replaced.
• With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance (Top, Second)
Standard:
Top 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.)
Second 0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Service Limit:
Top 0.18 mm (0.0071 in.)
Second 0.17 mm (0.0067 in.)
Piston Ring End Gap Inspection

• Place the piston ring inside the cylinder, using the piston
to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder were is low.
• Measure the gap [A] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap (Top, Second)
Standard: 0.20 ∼ 0.40 mm (0.0079 ∼ 0.0157 in.)
Cylinder Inside Diameter Inspection

• Take a side-to-side and a front-to-back measurement at
each of the 3 locations (total of 6 measurements) shown
in the figure.
If any of the measurements exceeds the service limit, the
cylinder will have to be bored to oversize and then honed.
Cylinder Inside Diameter
Standard: 75.980 ∼ 76.000 mm (2.9913 ∼ 2.9921
in.) and less than 0.01 mm (0.0004
in.) difference between any two
measurements
Service Limit: 76.10 mm (2.996 in.) or more than 0.05
mm (0.002 in.) difference between any
two measurements
Piston Diameter Inspection

• Measure the outside diameter [A] of the piston 10 mm (0.4
in.) [B] up from the bottom of the piston at right angles to
the direction of the piston pin.
If the measurement is under the service limit, replace the
piston.
Piston Diameter
Standard: 75.935 ∼ 75.950 mm (2.9896 ∼ 2.9902 in.)
Boring, Honing
When boring and honing a cylinder, note the following.
○Oversize piston requires oversize rings.
Oversize Piston and Rings
0.50 mm (0.020 in.) Oversize
○Before boring a cylinder, first measure the exact diam-
eter of the oversize piston, and then, according to the
standard clearance in the Specifications, determine the
rebore diameter. However, if the amount of boring nec-
essary would increase the inside diameter by more than
0.50 mm (0.020 in.), the crankcase must be replaced.
○Cylinder inside diameter must not vary more than 0.01
mm (0.0004 in.) at any point.
○Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
○In the case of rebored cylinder and oversize piston, the
service limit for the cylinder is the diameter that the cylin-
der was bored to plus 0.1 mm (0.004 in.) and the service
limit for the piston is the oversize piston original diameter
minus 0.15 mm (0.006 in.). If the exact figure for the re-
bored diameter is unknown, it can be roughly determined
by measuring the diameter at the base of the cylinder.
Crankshaft and Connecting Rods
Connecting Rod Removal
• Remove the connecting rods during the piston removal
(see Piston Removal).
Connecting Rod Installation
• Install the connecting rods during the piston installation
(see Piston Installation).
Crankshaft Removal
• Remove:
stallation chapter)
Cylinder Head (see Cylinder Head Removal in the En-
Alternator Rotor and Stator (see Alternator Rotor and
Stator Removal in the Electrical System chapter)
Camshaft (see Camshaft Removal)
Pistons and Connecting Rods (see Piston Removal)
Crankshaft
Crankshaft Installation
• Grease:
Oil Seal Lips
• Crankshaft
Apply engine oil:
Journal
• faces in. The cam timing
Install the crankshaft gear [A] with the chamfered side
mark [B] faces out.
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.
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.)
•○Measure the connecting rod twist.

With the big-end arbor [A] still on the V blocks [C], hold
the connecting rod horizontally and measure the amount
that the small end arbor [B] varies from being parallel with
the surface plate over a 100 mm (3.937 in.) length of the
arbor to determine the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.15/100 mm (0.0059/3.937 in.)
Connecting Rod Big End Side Clearance

Inspection
•○Measure connecting rod big end side clearance.
Insert a thickness gauge [A] between the connecting rod
big ends and either crank web to determine clearance.
If the clearance exceeds the service limit, replace the con-
necting rods with new ones and then check clearance
again. If the clearance is too large after connecting rod
replacement, the crankshaft must also be replaced.
Connecting Rod Big End Side Clearance
Standard: 0.3 ∼ 1.1 mm (0.012 ∼ 0.043 in.)
Connecting Rod Big End Bearing/Crankpin Wear
Inspection
Bearing/crankpin wear is measured using plastigauge
(press gauge), which is inserted into the clearance to be
measured. The plastigauge indicates the clearance by the
amount it is compressed and widened when the parts are
assembled.
• Measure the bearing/crankpin clearance.
○Remove the connecting rod big end cap and wipe the big
end bearing and crankpin surface clean of oil.
○Cut a strip of plastigauge to bearing width, and place the
strip [A] on the crankpin for the connecting rod parallel to
the crankshaft so that the plastigauge will be compressed
between the crankpin and the bearing.
○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)
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.)
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.
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.)
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.)
Crankshaft Runout Inspection

•○Measure the crankshaft runout.
Set the crankshaft in a flywheel alignment jig or on V
blocks.
○Set a dial against both bearing journals.
○Turn the crankshaft slowly to measure the runout. The dif-
ference between the highest and lowest dial gauge read-
ings (TIR) is the amount of runout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard: Less than TIR 0.02 mm (0.0008 in.)
Crankshaft Main Bearing/Journal Wear Inspection

• Measure the diameter [A] of the crankshaft main journal.
If the journal has worn past the service limit, replace the
crankshaft with a new one.
Crankshaft Main Journal Diameter
Standard: 33.959 ∼ 33.975 mm (1.3370 ∼ 1.3376 in.)
• Measure
bearing.
the inside diameter [A] of the crankshaft main
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.)
Breather Valve
Breather Valve Removal
• Remove:
Alternator and Stator (see Alternator and Stator Re-
Breather Cover Bolts [A]
Breather Cover [B]
• Remove:
Breather Valve [A]
Breather Valve Installation

• Place the reed valve on the seat so that there is a slight
gap between the valve and the seat.
Mounting Screw [A]
Back Plate [B]
Reed Valve [C]
Gap [D]
• 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.
Breather Valve Inspection

• Inspect the reed valve for breakage, hair cracks or distor-
tion, replace it if necessary.
• Inspect the back plate for damage or rough contact sur-
face, replace it if necessary.
• Inspect the valve seating surface. The surface should be
free of nicks or burrs.
TRANSMISSION 10-1
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.
10-4 TRANSMISSION
Exploded View
TRANSMISSION 10-5
Exploded View
Torque
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.
TO: Apply transmission oil.
10-6 TRANSMISSION
Exploded View
TRANSMISSION 10-7
Exploded View
Torque
N·m kgf·m ft·lb
1 Bearing Holder 118 12.0 87.0 MO
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)
10-8 TRANSMISSION
Exploded View
(KAF620P)
TRANSMISSION 10-9
Exploded View
Torque
N·m kgf·m ft·lb
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.
10-10 TRANSMISSION
Specifications

Transmission Oil
Type API "GL-6" Hypoid gear oil – – –
Viscosity SAE 90: above 5°C (41°F) – – –
SAE 80: below 5°C (41°F) – – –
Capacity:
KAF620M/N 2.5 L (2.6 US qt) – – –
KAF620P 2.2 L (2.3 US qt) – – –
Oil Level Between H and L lines on dipstick – – –
Transmission and Shift
Mechanism
Shift Arm Pin Diameter 7.95 ∼ 8.00 mm (0.313 ∼ 0.315 in.) 7.8 mm (0.307 in.)
Shifter Block Inside Diameter 8.05 ∼ 8.10 mm (0.317 ∼ 0.319 in.) 8.2 mm (0.323 in.)
Shifter Block Outside Diameter 13.95 ∼ 14.00 mm (0.549 ∼ 0.551 in.) 13.8 mm (0.543 in.)
Shifter Groove Width 14.0 ∼ 14.2 mm (0.551 ∼ 0.559 in.) 14.3 mm (0.563 in.)
Drive Chain 20-Link Length 158.76 ∼ 159.18 mm (6.250 ∼ 6.267 in.) 161.2 mm (6.346 in.)
Hi/Low Gears And Shift
Mechanism
2WD/4WD Shift Mechanism
(KAF620M/N)
Differential Gears And Shift
Mechanism
Shift Arm Pin Diameter 8.4 ∼ 8.6 mm (0.331 ∼ 0.339 in.) 8.3 mm (0.327 in.)
TRANSMISSION 10-11
Special Tools and Sealant
Outside Circlip Pliers: Hexagon Wrench, Hex 32:
57001-144 57001-1194
Oil Seal & Bearing Remover: Liquid Gasket, TB1105B:

57001-1058 92104-002
Bearing Driver Set:

57001-1129
10-12 TRANSMISSION
Transmission Oil
NOTICE
Vehicle operation with insufficient, deteriorated or
contaminated transmission oil will cause acceler-
ated wear and may result in transmission failure.
Transmission Oil Level Inspection

NOTE
○If the vehicle has just been used wait several minutes
for all the oil to settle down.
• Park the vehicle on level ground, and tilt up the cargo bed.
• insert it intothetheoil filler
Unscrew filler cap [A], wipe its dipstick [B] dry, and
opening but DO NOT SCREW IT IN.
• 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)
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]
Transmission Case Installation

• Adjust the transmission case mounting position (see En-
gine Installation in the Engine Removal/Installation chap-
ter).
• Replace the transmission case mounting nuts with new
ones.
• Tighten:
Torque - Transmission Case Mounting Nuts: 44.1 N·m (4.5
kgf·m, 33 ft·lb)
10-14 TRANSMISSION
Transmission Case
• Install (Optional Parts):

Speedometer Gear [A]
Washer [B]
O-ring [C]
Bushing [D]
Oil Seal [E]
Thick Holder [F]
Thin Holder [G]
Bolt [H]
• Adjust:
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]
Transmission Case Assembly

• Check to see that the transmission case knock pins [A]
are in place. If any one of them has been removed, re-
place it with a new one.
• Apply liquid gasket:
Transmission Case Mating Surface
Sealant - Liquid Gasket, TB1105B: 92104-002
• Apply grease:
Oil Seal Lips
• Tighten:
Torque - Transmission Case Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
TRANSMISSION 10-15
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.
• Put the shift lever [A] in the "L" (LOW) position.
• Using the shift shaft lever [A] temporarily set the shift arm
[B] in forward or reverse position as shown.
• Put the differential shift lever [A] in "LOCK" position.

10-16 TRANSMISSION
• 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].
• Line up the punch mark [A] on the shift arm, projection

[B] on the transmission case and slit opening in the shift
shaft lever [C].
• Tighten:
Shift Shaft Lever Nut [D]
Shift Shaft Lever Clamp Bolt [E]
• Hold the shift shaft lever [A] in the low range position
turning fully clockwise, and then push the outer cable [B]
lightly rearward to remove the cable free play.
• 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
• 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].
• Line up the punch mark [A] on the shift arm, projection

[B] on the transmission case and slit opening in the shift
shaft lever [C].
• Tighten:
Shift Shaft Lever Nut [D]
Shift Shaft Lever Clamp Bolt [E]
• Hold the shift shaft lever [A] in the neutral position, and
then pull the outer cable [B] lightly forward to remove the
cable free play.
NOTE
○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-
• Check the shift lever position (see Shift Lever Position

Inspection).
10-18 TRANSMISSION
Shift Lever Position Inspection
• Start the engine and put the shift lever in "N" (NEUTRAL)
or "L" (LOW) position.
• Move the shift lever [A] slowly to the direction of the arrow
on the figure. At this time, increase the engine speed
slightly.
• Check the grinding noise at the specified positions [B] and
[C].
If the position of the grinding noise is far from the specified
position, adjust the shift lever position (see Shift Lever
Position Adjustment).
Shift Lever Position Adjustment
• Loosen the hi/low shift cable adjuster nuts [A] and [B].
• 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
• Adjust the transmission shift cable and set the transmis-

sion shift lever [A] in the correct position as follows.
○When the shift lever moving to right and left, the gaps
between [B] and [C] are same.
○When the outer cable moving forward, the shift lever
moves upward.
○When the outer cable moving rearward, the shift lever
moves downward.
•Tighten:
Transmission Shift Cable Adjuster Nuts
TRANSMISSION 10-19
Transmission Shift Cable Inspection
• With the cable disconnected at both ends,
should move freely within the cable housing.
the cable
If the cable movement is not free, if the cable is frayed, or

if the housing is kinked, replace the cable.
Transmission Removal
• Remove:
Hi/Low Shift Gears (see Hi/Low Gear and Shift Mecha-
nism Removal)
2WD/4WD Shift Mechanism (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
• Remove:
Circlips [A]
Driven Shaft Reverse Sprocket [B]
Driven Shaft Forward Gear [C]
Driven Shaft [D]
Transmission Installation
• Replace all circlips that were removed with new ones.
NOTE
○Always install circlips [A] so that the opening [B] is
aligned with a spline groove. To install a circlip without
damage, first fit the circlip onto the shaft [C] and then
expand it just enough to install. Hence, use a suitable
gear to push the circlip into place.
• Apply transmission oil:

Drive and Driven Shafts
Forward Gears
Reverse Sprockets
Drive Chains
• Apply grease:
Oil Seal Lips
Shift Arm Positioning Ball and Spring
• Install the shifter [A] so that the groove [B] is away from
the forward gear [C].
• Tighten:
Torque - Shift Arm Positioning Bolt: 36.5 N·m (3.7 kgf·m,
27 ft·lb)
• Check that each gear, sprocket, and shifter spins or slides
freely on its shaft without binding after assembly.
Transmission and Shift Mechanism Inspection
• Visually inspect the forward gears, reverse sprockets,
gear and shaft bushings [A], drive chains, and shifter.
• Replace parts worn beyond the service limit.
TRANSMISSION 10-21
Shift Arm Pin Diameter [A]
Standard: 7.95 ∼ 8.00 mm (0.313 ∼ 0.315 in.)
Shifter Block Inside Diameter [B]

Standard: 8.05 ∼ 8.10 mm (0.317 ∼ 0.319 in.)
Shifter Block Outside Diameter [C]

Standard: 13.95 ∼ 14.00 mm (0.549 ∼ 0.551 in.)
Shifter Groove Width [D]

Standard: 14.0 ∼ 14.2 mm (0.551 ∼ 0.559 in.)
Drive Chain 20-Link Length [B]

Standard: 158.76 ∼ 159.18 mm (6.250 ∼ 6.267 in.)
Force [A]
1st Pin [C]
2nd Pin [D]
21st Pin [E]
10-22 TRANSMISSION
Hi/Low Gears and Shift Mechanism
The KAF620P model is not equipped with a Low gear.
Hi/Low Shift Cable Installation
• Refer
lation.
to the Transmission and Hi/Low Shift Cables Instal-
Hi/Low Shift Cable Inspection

• With the cable disconnected at both ends,
should move freely within the cable housing.
the cable

Hi/Low Gear and Shift Mechanism Removal

• Remove:
Bevel Gear Case (see Bevel Gear Case Removal in the
Final Drive chapter)
Hi/Low Shift Shaft Lever [A]
2WD/4WD Shift Cable Lower End [B] and Cable Bracket
• 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
• Remove:
Circlip [A]
Washer [B]
Low Gear [C]
Collar
• Remove:
Bolt [A]
Holder [B]
• Remove:
Retaining Pin [A]
Shift Shaft and Arm [B]
Hi/Low Gear and Shift Mechanism Installation

Hi/Low Gears
Shifter
• Apply grease:
Oil Seal Lips
• Replace the circlip that was removed with a new one.
NOTE
○Always install the circlip [A] so that the opening [B] is
• Install the shifter [A] so that the large dogs [B] face to the
low gear [C].
10-24 TRANSMISSION
• 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.
• Insert the shift shaft [A] in the gear case [B].

• Touch [C] the lever [D] of the shift shaft to lib [E].
• Fit the shift arm pins [A] into the shifter grooves [B] and
install the hi/low gear case.
• Tighten:
Torque - Hi/Low Gear Case Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)
• Install the retaining pin [A].

• Apply grease to the O-ring [B] and install the holder [C].
• Check that
Tighten the bolt [D].
• its shaft without
each gear and shifter spins or slides freely on
binding after assembly.
TRANSMISSION 10-25
Hi/Low Gear and Shift Mechanism Inspection
• Visually inspect the hi/low gears, shifter, and low gear
bushing [A].
If they are damaged or worn excessively, replace them.

Shifter Block Outside Diameter [A]
Standard: 13.95 ∼ 14.00 mm (0.549 ∼ 0.551 in.)
Shifter Groove Width [B]

Standard: 14.05 ∼ 14.15 mm (0.553 ∼ 0.557 in.)
10-26 TRANSMISSION
2WD/4WD Shift Mechanism (KAF620M/N)
2WD/4WD Shift Cable Adjustment
• Put the shift lever [A] in the 2WD position.
• Install the 2WD/4WD shift cable [A] to the shift shaft lever
[B] and cable bracket [C].
• Put the shift lever [A] in the 4WD position.
• Turn the shift shaft lever [A] counterclockwise until the

lever is stopped by engaging the shifter with the drive
bevel gear shaft.
• Screw in the upper adjuster nut [B] by hand until the inner
cable [C] has no slack while holding the shift lever in the
4WD position.
• Tighten the lower adjuster nut [D] securely.
2WD/4WD Shift Cable Lubrication

• Whenever the shift cable is removed or in accordance
tenance chapter, lubricate the cable.
nance chapter.
TRANSMISSION 10-27
2WD/4WD Shift Cable Inspection
• With the cable disconnected at both ends, the cable
should move freely [A] within the cable housing.
If the cable does not move freely after lubricating, if the
cable is frayed, or if the housing is kinked, replace the
cable.
2WD/4WD Shift Mechanism Removal

• Remove:
Hi/Low Gear Case (see Hi/Low Gear and Shift Mecha-
nism Removal)
Shift Shaft Stop Bolt [A] and Washer
• 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
2WD/4WD Shift Mechanism Installation

• Apply transmission oil to the following parts.
Speedometer Gear
Shifter
10-28 TRANSMISSION
• Replace the circlip that was removed with a new one.

NOTE
○Always install the circlip [A] so that the opening [B] is
• Install the collar [A].

• [C] faces tospeedometer
Install the
the inside.
gear [B] so that the stepped side
• Install the circlip.

• Install the shifter so that the dogs [A] face to the outside.
• Insert the shift shaft [A] in the gear case.

• Install the O-ring [B] and apply molybdenum disulfide
grease to the O-ring.
• When the hi/low gear case installing, refer to the Hi/Low

Gear and Shift Mechanism Installation.
TRANSMISSION 10-29
• Push the shift shaft [A] as shown in the figure.

• Washer [B]
Install:
Shift Shaft Stop Bolt [C]

• Tighten:
Torque - Shift Shaft Stop Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)
• Wipe off any protruding grease.
• Install the spring [A].

• hold it. shift shaft [B] counterclockwise until it is stop and
Turn the
• 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]
Shifter Block Outside Diameter
Standard: 13.95 ∼ 14.00 mm (0.549 ∼ 0.551 in.)
Shifter Groove Width

Standard: 14.0 ∼ 14.2 mm (0.551 ∼ 0.559 in.)
10-30 TRANSMISSION
Differential Gears and Shift Mechanism
Differential Shift Cable Adjustment
• Put the shift lever [A] in the UNLOCK position.
• Set the shift shaft lever [A] in the UNLOCK position.

• loosened.the adjuster nut [B] until the inner cable is slightly
Loosen
• Tighten the adjuster nut [C] securely.
Differential Shift Cable Lubrication

• Whenever the shift cable is removed, or in accordance
tenance chapter, lubricate the cable.
nance chapter.
Differential Shift Cable Inspection
Differential Shift Mechanism Removal

• Remove:
Drive Shafts and Axles
Shift Shaft Stop Bolt [A]
Shift Shaft Lever Mounting Nut [B]
Shift Shaft Lever [C]
Spring [D]
Shift Shaft and Arm [E]
TRANSMISSION 10-31
Differential Shift Mechanism Installation
• Apply grease:
Shift Shaft O-ring
• Install the shift shaft lever [A] to the shift arm [B] as shown.
Torque - Shift Shaft Stop Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Differential Shift Mechanism Inspection

• Visually inspect:
Splines on Drive Shaft [A]
Splines on Shifter [B]
Dogs [C] on Shifter
Shifter Groove [D]
• Visually inspect:
Shift Arm Pin [A]
Dogs on Differential Gear Housing [B]

Shift Arm Pin Diameter [A]
Standard: 8.4 ∼ 8.6 mm (0.331 ∼ 0.339 in.)
Shifter Groove Width [B]

Standard: 9.0 ∼ 9.1 mm (0.354 ∼ 0.358 in.)
Differential Gear Removal

• Split
ting).
the transmission case (see Transmission Case Split-
• Remove:
Differential Gear Assembly [A]
10-32 TRANSMISSION
• Remove:
Differential Gear Housing Bolts [A]
Final Gear [B]
• Remove:
Housing Cover [A]
Knock Pin [B]
Side Gear [C]
Spacer [D]
• Remove:
Knock Pins [A]
Retaining Pin [B]
Pinion Gear Shaft [C]
Pinion Gears [D]
Spacers
Side Gear [E]
Spacer
Differential Gear Installation

Side Gears
Pinion Gears
Differential Gear Housing Bolts
• Tighten:
Torque - Differential Gear Housing Bolts: 57 N·m (5.8
kgf·m, 42 ft·lb)
If the backlash of the differential gears cannot keep, re-

place the spacers [A] to thinner spacers.
Spacers
Thickness Part Number
1.2 mm (0.047 in.) 92200-0021
1.0 mm (0.039 in.) 92200-1044
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 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
• Apply Molybdenum disulfide oil:

Drive Bevel Gear Shaft Bearing Holder [A]
• Install the drive bevel gear shaft bearing holder so that
the projections [B] faces to outside.
• Tighten:
Torque - Bearing Holder: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
• Using a press and the bearing driver set, install the new
bearings and/or new oil seals.
Special Tool - Bearing Driver Set: 57001-1129
Ball Bearing Inspection

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

•○Check the needle bearing.
The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bear-
ing, replace it.
Oil Seal Inspection
• Visually inspect the oil seal.
Replace it if the lips are misshapen, discolored (indicat-
ing that the rubber has deteriorated), hardened, or been
otherwise damaged.
TRANSMISSION 10-35
Transmission Sectional Figure
KAF620M/N
10-36 TRANSMISSION
Transmission Sectional Figure
KAF620P
WHEELS/TIRES 11-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Wheel Alignment .................................................................................................................... 11-5
Toe-in Adjustment ............................................................................................................. 11-5
Wheels (Rims) ........................................................................................................................ 11-7
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
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

Wheel Alignment
Caster 7.5° (non-adjustable) – – –
Camber 0.8° (non-adjustable) – – –
Toe-in 0 ∼ 20 mm (0 ∼ 0.79 in.) at 1G – – –
Wheels (Rims)
Rim Size:
Front and Rear 10 × 8.5 AT – – –
Tires
Standard Tire:
Front and Rear 23 × 11.00-10 – – –
DUNLOP KT869, Tubeless – – –
23 × 11.00-10 – – –
DURO DI-K968, Tubeless – – –
Tire Air Pressure (when Cold):
Front 69 kPa (0.70 kgf/cm², 10 psi) – – –
Rear 167 kPa (1.70 kgf/cm², 24 psi) – – –
Maximum Tire Air Pressure (to seat 250 kPa (2.5 kgf/cm², 36 psi) – – –
beads, when cold)
Tire Tread Depth 13.2 mm (0.52 in.) 3 mm (0.12 in.)
WHEELS/TIRES 11-5
Wheel Alignment
Toe-in is the amount that the front wheels are closer to-
gether in front than at the rear at the axle height. When
there is toe-in, the distance A (rear) is greater than B (front)
as shown in the figure. The purpose of toe-in is to prevent
the front wheels from getting out of parallel at any time, and
to prevent any slipping or scuffing action between the tires
and the ground. If toe-in is incorrect, the front wheels will be
dragged along the ground, scuffing and wearing the tread
knobs.
Caster and camber are built-in and require no adjustment.
A (Rear) - B (Front) = Amount of Toe-in
(Distance A and B are measured at hub height)
Toe-in Adjustment
• Lift the front wheels off the ground.
• Apply
tires.
a heavy coat of chalk near the center of the front
• Using a needle nose scriber, make a thin mark near the

center of the chalk coating while turning the wheel.
• Set the wheels so that the marks on the tires are at the
front side and at the level of the axle height.
• Ground the front wheels.
• At the level of thewheel
Set the steering straight ahead.
• tween the scribed lines
axle height, measure the distance be-
with a measure.
• tires are at the rear side and atuntilthethe
Move the vehicle rearward marks on the front
same level as the axle.
• Measure the distance between the scribed lines.
• ment of the rear
Subtract the measurement of the front from the measure-
to get the toe-in.
Toe-in of Front Wheels
Standard: 0 ∼ 20 mm (0 ∼ 0.79 in.) at 1G
If the toe-in is not the specified value, perform the follow-
ing procedure.
• 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.
If the tire is removed, inspect the air sealing surfaces [A]

of the rim for scratches or nicks. Smooth the sealing sur-
faces with fine emery cloth if necessary.
Wheel (Rim) Replacement

• Remove the wheel (see Wheel Removal).
• Remove the valve
Disassemble the tire from the rim.
• stem and discard it.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
Plastic Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
11-8 WHEELS/TIRES
Wheels (Rims)
•○Install a new air valve in the new rim.

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

• Install the wheel (see Wheel Installation).
WHEELS/TIRES 11-9
Tires
Tire Removal
• Remove:
Wheel (see Wheel Removal)
Valve Core (Let out the air)
• Lubricate the tire beads and rim flanges on both sides of
the wheel with a soap and water solution, or water [A].
This helps the tire beads slip off the rim flanges.
NOTICE
Do not lubricate the tire beads and rim flanges with
engine oil or petroleum distillates because they will
deteriorate the tire.
• Remove the tire from the rim using a suitable commer-

cially available tire changer.
NOTE
○The tires cannot be removed with hand tools because
they fit the rims tightly.
Tire Installation
• Inspect the rim.
• Replace thetireairforvalve
Check the wear and damage.
• with a new one.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
• Lubricate the tire beads and rim flanges with a soap and
water solution, or water.
WARNING
Do not use any lubricant other than a water and
soap solution, or water to lubricate the tire beads
and rim because it may cause tire separation, and
a hazardous condition may result.
• Install the tire on the rim using a suitable commercially

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

vent the tire from slipping off.
• Inflate the tire until the tire beads seat on the rim.
Maximum Tire Air Pressure (to seat beads, when cold)
Front and Rear: 250 kPa (2.5 kgf/cm², 36 psi)
WARNING
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)
• Install the wheel (see Wheel Installation).

• and dry the
Wipe off the soap and water solution, or water on the tire,
tire before operation.
WARNING
Water or soap solution on the tire bead can cause
tire separation and an accident resulting in serious
injury or death. Do not operate the vehicle until any
water or soap solution applied to the bead has com-
pletely dried.
Tire Inspection
• 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
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.
12-4 FINAL DRIVE
Exploded View
FINAL DRIVE 12-5
Exploded View
Torque
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
10. KAF620M/N
11. KAF620M9 ∼ MC/N9/P9 ∼ PC
G: Apply grease.
12-6 FINAL DRIVE
Specifications

Front Final Gear Case
Gear Case Oil:
Type API "GL-5 or GL-6" hypoid gear oil for – – –
LSD (Limited Slip Differential gears)
Viscosity SAE90, or SAE140 – – –
Capacity 0.4 L (0.4 US qt) – – –
Oil Level Filler opening level – – –
LSD Clutch Torque 7.8 ∼ 13 N·m – – –
(0.8 ∼ 1.3 kgf·m, 69 ∼ 110 in·lb)
Outside Friction Plate Thickness 2.3 ∼ 2.4 mm (0.091 ∼ 0.094 in.) 2.1 mm (0.083 in.)
Inside Friction Plate Thickness 2.7 ∼ 2.8 mm (0.106 ∼ 0.110 in.) 2.4 mm (0.094 in.)
Pinion Gear Bearing Preload 1.5 ∼ 3.0 N (0.15 ∼ 0.30 kgf, 0.33 ∼
– – –
0.66 lb)
Pinion Gear Bearing Preload Torque 0.3 ∼ 0.6 N·m – – –
(0.03 ∼ 0.06 kgf·m, 2.6 ∼ 5.2 in·lb)
Bevel Gear Backlash 0.11 ∼ 0.57 mm (0.0043 ∼ 0.0224 in.) – – –
(at ring gear tooth)
Bevel Gear Case
Bevel Gear Backlash 0.07 ∼ 0.15 mm (0.0028 ∼ 0.0059 in.) – – –
(at middle of gear dog side on drive
gear shaft)
FINAL DRIVE 12-7
Special Tools
Bearing Puller: Socket Wrench:
57001-135 57001-1283
Outside Circlip Pliers: Pinion Gear Holder:

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

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

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

57001-1281 57001-1676
12-8 FINAL DRIVE
Front Final Gear Case Oil Level Inspection
• Park the vehicle so that it is level, both side-to-side and
front-to-rear.
• Remove:
Front Final Gear Case Skid Plate Nuts and Bolts [A]
Front Final Gear Case Skid Plate [B]
• 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
FINAL DRIVE 12-9
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]
Front Final Gear Case Installation

• Run the gear case vent hose correctly (see Cable, Wire,
and Hose Routing section in the Appendix chapter).
• Replace the gear case mounting nuts with new ones.
• Tighten:
Torque - Gear Case Bracket Bolts: 44.1 N·m (4.5 kgf·m, 33
ft·lb)
Gear Case Mounting Nuts: 44.1 N·m (4.5 kgf·m, 33
ft·lb)
• Adjust:
Front Final Gear Case Oil (see Front Final Gear Case
Oil Change in the Periodic Maintenance chapter)
12-10 FINAL DRIVE
Front Final Gear Case Disassembly
• Remove:
Front Final Gear Case (see Front Final Gear Case Re-
moval)
Bearing Housing Nuts [A]
Pinion Gear Unit [B]
• Remove:
Spacers [A] (both sides)
• Remove
bolts [B].
the ring gear cover bolts, starting with the smaller
Larger Bolts [C]

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

• Visually check the pinion gear and ring gear for scoring,
chipping, or other damage.
Replace the bevel gears as a set if either gear is damaged
since they are lapped as a set in the factory to get the best
tooth contact.
• Check that the ring gear is installed on the correct side of
the differential caps [A] as shown.
• Install the following parts in the order listed.
Differential Unit and Ring Gear
Ring Gear Shim [B]
Ring Gear Cover
Pinion Gear Unit
FINAL DRIVE 12-11
• 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
Ring Gear Bolts [A]

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

tion) and the other differential unit parts. Replace any
damaged parts.
• Measure and record the thickness of the original clutch
spring shim(s).
• Apply specified gear oil to the differential unit parts.
• Note direction and position of the friction plate and the
clutch spring.
Clutch Spring Shim(s) [A]
Clutch Spring [B]
Outside Friction Plate [C]
Steel Plate [D]
Inside Friction Plate [E]
12-12 FINAL DRIVE
• Be sure to assemble the differential unit and inspect the

clutch torque (see LSD Clutch Torque Inspection).
Tapped Holes [A] for Ring Gear
Mark [B] for assembly
• Install the front axles [C] to center the steel plates.
Differential Case Torx Bolts [D]
• Tighten:
Torque - Differential Case Torx Bolts: 32 N·m (3.3 kgf·m, 24
ft·lb)
Ring Gear Bolts: 49 N·m (5.0 kgf·m, 36 ft·lb)
LSD Clutch Torque Inspection

• After assembling the differential unit and ring gear, check
the LSD clutch torque.
• Remove the ring gear from the differential unit [A].
• Hold one offront
Insert both axles [B] in the unit.
• Install the hubthenutfronton axles with a vise.
• Measure the clutch torque using axle.
the other
• the wrench evenly. a torque wrench [C]. Turn
○The clutch torque is the mean torque reading during about

a quarter turn of the wrench.
LSD Clutch Torque
Standard: 7.8 ∼ 13 N·m (0.8 ∼ 1.3 kgf·m, 69 ∼ 110 in·lb)
If the clutch torque is out of the specified range, disas-
semble the differential unit (see Differential Unit and Ring
Gear Disassembly) and replace either of the clutch spring
shim(s).
•Also, check the clutch plates and replace them as neces-
sary (see LSD Clutch Plate Inspection).
•To increase clutch torque, increase the thickness of the
shim(s).
○Change the thickness a little at a time.
•Recheck the clutch torque and readjust as necessary.
0.8 mm (0.031 in.) 92180-1121
1.0 mm (0.039 in.) 92180-1122
1.2 mm (0.047 in.) 92180-1123
1.4 mm (0.055 in.) 92180-1124
1.6 mm (0.063 in.) 92180-1125
FINAL DRIVE 12-13
LSD Clutch Plate Inspection
• Visually inspect the friction plates and steel plates to see
if they show any signs of seizure, overheating, or uneven
wear.
If any plates show signs of damage, or if the friction plates
have worn past the service limit, replace the friction plates
and steel plates as a set.
Outside Friction Plate [A]
Inside Friction Plate [B]
Outside Friction Plate Thickness
Standard: 2.3 ∼ 2.4 mm (0.091 ∼ 0.094 in.)
Inside Friction Plate Thickness

Standard: 2.7 ∼ 2.8 mm (0.106 ∼ 0.110 in.)
Pinion Gear Unit Disassembly

• Remove the pinion gear unit (see Front Final Gear Case
Disassembly).
• Pry open the toothed washer tab [A] on the pinion gear
slotted nut [B].
• Unscrew the pinion gear slotted nut.

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

• The pinion gear and ring gear are lapped as a set in the
factory to get the best tooth contact. They must be re-
placed as a set.
•Visually inspect the tapered roller bearings for abrasion,
color change, or other damage.
If there is any doubt as to the condition of a bearing, re-
place the bearing housing and the bearings as a set.
•Be sure to check and adjust the pinion gear bearing
preload and the bevel gear backlash and tooth contact,
when any of the backlash-related parts are replaced (see
Front Final Bevel Gear Adjustment).
○When the pinion gear slotted nut is loosened, even if the
purpose is not to replace the parts, check and adjust the
bearing preload.
12-14 FINAL DRIVE
• Fit the toothed washer claw [A] into the shaft.

• surfacemolybdenum
Apply disulfide oil to the threads and seating
of the pinion gear slotted nut, and tighten it.
Torque - Pinion Gear Slotted Nut: 118 N·m (12.0 kgf·m, 87.0
ft·lb)
If none of the toothed washer tabs [B] align, tighten the
nut further just enough to align one of the tabs with a slot
[C] in the nut.
• Bend the tab over the nut.
Front Final Bevel Gear Adjustment

In order to prevent one gear from moving away from the
other gear under load, the tapered roller bearings must be
properly preloaded. Also the backlash (distance one gear
will move back and forth without moving the other gear) and
tooth contact pattern of the bevel gears must be correct to
prevent the gears from making noise and being damaged.
Above three adjustments are of critical importance and
must be carried out following the correct sequence and
method.
• When any one of the backlash-related parts are replaced
or the pinion gear nut is loosened; even if the purpose
is not to replace the parts, check and adjust the bearing
preload, the bevel gear backlash, and tooth contact by
replacing shims.
• The amount of backlash is influenced by the ring gear
position more than by the pinion gear position.
• Tooth contact location is influenced by pinion gear posi-
tion more than by ring gear position.
FINAL DRIVE 12-15
Bearing Preload Adjustment:
•Check and adjust the bearing preload in the following
cases.
○When any of the parts listed below are replaced with new
ones.
Pinion Gear
Collar
Shim
Tapered Roller Bearings
Pinion Gear Bearing Housing [A]
Oil Seal Collar
○When the pinion gear slotted nut [B] is loosened; even if
the nut is not removed.
•Install the pinion gear bearing housing and tighten the
pinion gear slotted nut to the specified torque (see Pinion
Gear Unit Disassembly/Assembly).
•Do not install the oil seal and O-rings, and do not lock the
washer until the correct bearing preload is obtained.
NOTICE
To start with, choose a shim or collar so that the
bearings are just SNUG with NO play but also with
NO preload.
An over-preload on the bearings could damage the
bearings.
• 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
FINAL DRIVE 12-17
If the preload is out of the specified range, replace the
collar and/or shim(s).
○To increase preload, decrease the size of the shim(s)
or collar. To decrease preload, increase the size of the
shim(s) or collar.
•Recheck the bearing preload, and readjust as necessary.
• Measure the bearing preload using a spring scale.

Using Spring Scale
Pinion Gear Bearing Preload:
1.5 ∼ 3.0 N (0.15 ∼ 0.30 kgf, 0.33 ∼ 0.66 lb)
○Hook the spring scale [A] on the handle at a point 200
mm (7.87 in.) [B] apart from the center of the gear shaft.
Hold the bearing housing in a vise so that the gear shaft
is vertical.
○Apply force to the handle horizontally and at a right angle
to it.
Special Tool - Pinion Gear Holder: 57001-1281 [C]
• Measure the bearing preload using a torque wrench [A].

Using Torque Wrench
Pinion Gear Bearing Preload Torque:
0.3 ∼ 0.6 N·m (0.03 ∼ 0.06 kgf·m, 2.6 ∼ 5.2 in·lb)
Special Tool - Pinion Gear Holder: 57001-1281 [B]
Backlash Adjustment
• Check and adjust the gear backlash when any of the
backlash-related parts are replaced with new ones.
• Clean any dirt and oil off the bevel gear teeth.
• 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).
•Recheck the backlash, and readjust as necessary.
12-18 FINAL DRIVE
• Move the front axle back and forth [A].

Dial Gauge [C]
Bevel Gear Backlash
Standard: 0.11 ∼ 0.57 mm (0.0043 ∼ 0.0224 in.) (at
ring gear tooth)
Tooth Contact Adjustment

• Apply
gear.
checking compound to 4 or 5 teeth on the pinion
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
12-20 FINAL DRIVE
Bevel Gear Inspection
• Visually check the bevel gears [A] for scoring, chipping,
or other damage.
Replace the bevel gears as a set if either gear is dam-
aged.
Differential Gear Inspection

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

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

place it.

• Since the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement. Clean each bearing in a high flash-point sol-
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
• Spin the bearing by hand [A] to check its condition.
If the bearing [B] is noisy, does not spin smoothly, or has
any rough spots, replace it.
Oil Seal Inspection

• Visually inspect the oil seal.
otherwise damaged.
FINAL DRIVE 12-21
Bevel Gear Case (KAF620M/N)
Bevel Gear Case Removal
• Drain:
• Remove:
Propeller Shafts (see Propeller Shaft Removal)
Speed Sensor Lead Connector [A]
Bevel Gear Case Bolts [B]
Bevel Gear Case [C]
Bevel Gear Case Installation

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

• Remove:
Speed Sensor (see Speed Sensor Removal in the Elec-
trical System chapter)
Holder Nuts [A]
Cover [B]
Holder [C]
If the driven gear assembly is to be disassembled, loosen

the housing locknut [A].
Special Tools - Pinion Gear Holder [B]: 57001-1281
Socket Wrench [C]: 57001-1363
• Remove:
Driven Gear Assembly [A]
Driven Gear Shim(s) [B]
12-22 FINAL DRIVE
• 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
○Pressing the spring seat [C], remove the driven gear shaft
nut.
• Remove:
Bearing Holder [A]
Special Tool - Hexagon Wrench, Hex 40: 57001-1324 [B]
• Remove:
Ball Bearings
Special Tools - Oil Seal & Bearing Remover: 57001-1058
Bearing Driver Set: 57001-1129
Bevel Gear Case Assembly

• Install the housing locknut [A] so that the chamfered side
[B] faces to the bearing.
Driven Gear Shaft Nut
Bearing Holder
Housing Locknut
• Tighten:
Torque - Driven Gear Shaft Nut: 108 N·m (11.0 kgf·m, 79.7
ft·lb)
Bearing Holder: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
Housing Locknut: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
Bevel Gear Case Holder Nuts: 25 N·m (2.5 kgf·m,
18 ft·lb)
• Grease:
Holder Oil Seal Lips
FINAL DRIVE 12-23
Drive Bevel Gear Removal
• Remove:
Hi/Low Gear Case (see Hi/Low Gear and Shift Mecha-
nism Removal in the Transmission chapter)
• Hold the transmission gear holder [A] in a vise.
Special Tool - Transmission Gear Holder: 57001-1676
• 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]
Drive Bevel Gear Installation

• Check and adjust the bevel gear backlash and tooth con-
tact when any of the backlash-related parts are replaced
(see Bevel Gear Adjustment).
• Apply molybdenum disulfide oil:
Drive Gear Nut Seating Surface
• Tighten:
Torque - Drive Gear Nut: 118 N·m (12.0 kgf·m, 87.0 ft·lb)
12-24 FINAL DRIVE
Bevel Gear Adjustment
In order to prevent one gear from moving away from the
other gear under load, the backlash and tooth contact
pattern of the bevel gears must be correct to prevent the
gears from making noise and being damaged.
When replacing any one of the backlash-related parts, be
sure to check and adjust the backlash and tooth contact.
First adjust the backlash, and then tooth contact by replac-
ing shims.
These two adjustments are of critical importance and
must be carried out in the correct sequence, using the
procedures shown.
Backlash Adjustment
• Check and adjust the gear backlash when any of the
backlash-related parts are replaced with new ones.
• Install the drive gear with the primary shim and assemble
the driven gear with the primary shim. Do not install the
bevel gear case holder during adjustment.
•Clean any dirt and oil off the bevel gear teeth.
•Install the bevel gear case and tighten the case bolts.
○Check the backlash while tightening the case bolts. Stop
tightening them immediately if the backlash disappears
and change the shim to a thinner one.
•○Hold the driven gear shaft [A] with a vise.

Protect the driven gear shaft with aluminium plates [B].
• Set up a dial gauge [C] against the middle point [D] of the
gear dog side [E].
○The middle point is position at about 23.5 mm (0.925 in.)
[F] from center.
Gear Dog [G]
• To measure the backlash, turn the shaft clockwise and
counterclockwise. The distance between the highest and
lowest gauge reading is the amount of backlash.
If the backlash is not within the limit, replace the shim(s)
at the drive and/or driven gear. To increase backlash, de-
crease the thickness of the shim(s). To decrease back-
lash, increase the thickness of the shim(s).
Change the thickness a little at a time.
• Recheck the backlash, and readjust as necessary.
Bevel Gear Backlash
Standard: 0.15 ∼ 0.59 mm (0.0059 ∼ 0.0232 in.)
(at middle of gear dog side on drive
gear shaft)
FINAL DRIVE 12-25
Bevel Gear Case (Backlash-Related Parts)
1. Driven Gear Shim(s) 7. Driven Bevel Gear

2. Drive Gear Shim(s) 8. Hi/Low Gear Case
3. Driven Gear Shaft 9. Drive Gear Shaft
4. Bearing Housing 10. Ball Bearing
5. Bevel Gear Case 11. Gasket
6. Ball Bearing 12. Drive Bevel Gear
1. Driven Gear Shims

0.1 mm (0.004 in.) 92025-1859
0.15 mm (0.006 in.) 92025-1860
0.5 mm (0.020 in.) 92025-1861
0.8 mm (0.031 in.) 92025-1862
1.0 mm (0.039 in.) (primary) 92025-1858
1.2 mm (0.047 in.) 92025-1863
12-26 FINAL DRIVE
2. Drive Gear Shims
0.15 mm (0.006 in.) 92025-1573
0.2 mm (0.008 in.) 92025-1574
0.7 mm (0.028 in.) 92025-1534
0.8 mm (0.031 in.) 92180-0288
0.9 mm (0.035 in.) 92180-0289
1.0 mm (0.039 in.) (primary) 92180-0290
1.1 mm (0.043 in.) 92025-1575
1.2 mm (0.047 in.) 92180-0291
1.3 mm (0.051 in.) 92025-1533
Tooth Contact Adjustment
• bevel gear. compound to 4 or 5 teeth on the driven
Apply checking
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
Incorrect Tooth Contact Patterns
Example 1: Increase the thickness of the drive bevel gear
shim(s) by 0.05 mm (0.002 in.), and/or increase the thick-
ness of the driven bevel gear shim(s) by 0.05 mm (0.002
in.) to correct the pattern shown below. Repeat in 0.05 mm
(0.002 in.) steps if necessary.
[C] Bottom
[D] Top
[E] Heel
[F] Toe
Example 2: Decrease the thickness of the drive bevel gear

shim(s) by 0.05 mm (0.002 in.), and/or decrease the thick-
ness of the driven bevel gear shim(s) by 0.05 mm (0.002
in.) to correct the pattern shown below. Repeat in 0.05 mm
(0.002 in.) steps if necessary.
[C] Bottom
[D] Top
[E] Heel
[F] Toe
12-28 FINAL DRIVE
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.

it with engine oil.
• Spin the bearing by hand [A] to check its condition.
Oil Seal Inspection

• Inspect the oil seals.
otherwise damaged.
Damper Inspection
• Visually inspect the driven bevel gear [A], cam follower
[B], spring [C], and shaft [D].
Replace any part that appears damaged.
FINAL DRIVE 12-29
Propeller Shafts (KAF620M/N)
Propeller Shaft Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Tapping Screws [A]
Water Pipe Bracket Bolt [B]
Plate [C]
Screw [D]
• 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 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-

• Apply grease to the new O-ring on the front pinion gear.
• Put thethepropeller
Install front propeller shaft yoke [B] on the pinion gear.
• position. shaft bearing housing [C] at fully outside
• 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 Shaft Bearing Housing Removal

• Remove:
Front Propeller Shaft (see Propeller Shaft Removal)
Propeller Shaft Bearing Housing Cover Bolts [A] (Both
Sides)
Propeller Shaft Bearing Housing Covers [B] (Both Sides)
• Wipe off the grease.

• Stop Screws [A]
Remove:
Front Propeller Shaft [B]

Propeller Shaft Bearing Housing [C]
12-32 FINAL DRIVE
• Wipe off the grease.

• Remove the circlip [A].
• Remove the propeller shaft bearing housing cover [B].
Propeller Shaft Bearing Housing Installation

• Clean the front propeller shaft by wiping off the used
grease on it.
• Install:
Propeller Shaft Bearing Housing Cover [A]
New Circlip
• Insert the front propeller shaft in the propeller shaft bear-
ing housing [B].
• Tighten:
Torque - Stop Screws: 3.9 N·m (0.40 kgf·m, 35 in·lb)
• Apply grease about 8 g (0.28 oz) [C] into each cover.
• Install:
Propeller Shaft Bearing Housing Covers [A]
Propeller Shaft Bearing Housing Cover Bolts [B] (Both
Sides)
• Tighten:
Torque - Propeller Shaft Bearing Housing Cover Bolts: 3.4
N·m (0.35 kgf·m, 30 in·lb)
Propeller Shaft Inspection

• Visually inspect the splines of the propeller shafts.
If they are twisted, badly worn, or chipped, replace the
shafts.
• Check that the universal joint works smoothly without rat-
tling or sticking.
If it does not, the bearings of the joint are damaged. Re-
place the propeller shaft with a new one.
FINAL DRIVE 12-33
Drive Shaft and Axles
Front Axle Removal
• Remove:
Steering Knuckle (see Steering Knuckle Removal in the
Steering chapter)
Radiator Side Cover
Front Axle Cap Bolts [A]
Front Axle [B]
Front Axle Installation

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

• Remove:
Rear Wheels (see Wheel Removal in the Wheels/Tires
chapter)
Rear Brake Drums (see Brake Drum Removal in the
Brakes chapter)
Rear Brake Panel Assemblies (with Brake Pipes and
Hoses)
Rubber Bands [A]
Axles [B] and Axle Bracket [C]
• Slide the dust boots [D] from the drive shafts [E], and pull
the one of the axles from the drive shaft, and then the
other axle from the shaft.
• Tap [A] the outside of the rear axle [B], and pull it out from
the inside.
12-34 FINAL DRIVE
• Remove:
Drive Shaft Cap Bolts [A]
Drive Shaft [B] and Cap [C]
○Set the differential shift lever into the UN-LOCK position.
Rear Drive Shaft and Axle Installation

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

the small hole [A] in the boot is toward the axle side.
• Adjust:
Torque - Drive Shaft Cap Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Drive Shaft and Axle Inspection

• Visually inspect the splines of the drive shaft and axle.
If they are twisted, badly worn, or chipped, replace the
drive shaft and/or axle with a new one.
• Check that the universal joint and/or ball joint works
smoothly without rattling or sticking.
If it does not, the bearings of the joint are damaged. Re-
place the drive shaft and/or axle with a new one.
FINAL DRIVE 12-35
Dust Boot Inspection
• Visually inspect the boots [A] in accordance with the Peri-
odic Maintenance Chart or if the drive shafts or axles are
noisy during operation.
If the dust boot is torn, worn, deteriorated, or leaks
grease, replace it.
Front Axle Joint Boot Replacement

Outboard Joint Boot Removal
•Remove:
Front Axle (see Front Axle Removal)
•Tap the joint portion of the bands [A] with a suitable tool.
•Scrap the removed boot bands.
•Slide the joint boot [B] toward the inboard joint.
• 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
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]
• Place the special grease tube nozzle in the bore of the

housing and squeeze the tube [A] until the grease comes
out from the joint bearing.
• Tap the shaft end [A] straight with a plastic hammer until
it is locked by the circlip.
• Squeeze all of the special grease into the bearing housing

[A] and new boot [B].
FINAL DRIVE 12-37
• Pinch the small boot band [A] with a suitable tool [B] to
install it.
• Compress the axle assembly to the specified length while

relieving the air pressure inside the boot.
• Hold the axle at this setting.
Standard Length of Assembling:
Outboard: 254.5 mm (10.020 in.) [A]
○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
○Compress the suitable tool with a vice, if necessary.
• Be sure outside diameter of the band [A] is less than the

maximum diameter.
Maximum Outside Diameter of Band: 75.9 mm (2.99 in.)
12-38 FINAL DRIVE
Inboard Joint Boot Removal
• Remove:
Circlip [A]
Special Tool - Outside Circlip Pliers [B]: 57001-144
• Remove:
Collar [C]
Cap [D]
• Remove:
• 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 the retaining ring [A].

• Separate the bearing cup from the axle shaft.
• Remove the steel balls [A].

• Slide the cage [B] toward the outboard joint.
• Remove:
Circlip [A]
FINAL DRIVE 12-39
• Remove:
Inner Race [A]
Cage [B]
Inboard Joint Boot [C]
Inboard Joint Boot Installation

• Install:
New Small Band [A]
New Inboard Joint Boot [B]
Cage [C]
• Install the inner race [A] so that the flat serration side [B]
faces outboard joint.
• Install:
Circlip [A]
• 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
• Squeeze about half a tube (30 grams) of the special

grease [A] into the bearing cup [B].
• Insert the balls and cage assembly in the bearing cup
strongly.
• 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].
• Squeeze the remaining special grease into the bearing

cup [A] and new joint boot [B].
• Pinch the small boot band [A] with a suitable tool [B] to
install it.
FINAL DRIVE 12-41
• Compress the axle assembly to the specified length while

relieving the air pressure inside the boot.
• Hold the axle at this setting.
Standard Length of Assembling:
Outboard 210..3 mm (8.280 in.) [A]
○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
○Compress the suitable tool with a vice, if necessary.
• Be sure the outside diameter of the band [A] is less than

the maximum diameter.
Maximum Outside Diameter of Band: 68.9 mm (2.71 in.)

it with engine oil.
• Spin [A] the bearing by hand to check its condition.
12-42 FINAL DRIVE
Grease Seal Inspection
• Visually inspect the grease seals.
Replace if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened, or been oth-
erwise damage.
BRAKES 13-1
Brakes
Table of Contents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-6
Special Tools .......................................................................................................................... 13-7
Brake Fluid ............................................................................................................................ 13-8
Brake Fluid Recommendation........................................................................................... 13-8
Brake Fluid Level Inspection............................................................................................. 13-8
Brake Fluid 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
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).
G: Apply grease.
HG: Apply high-temperature grease.
Si: Apply silicone grease.
WL: Apply soap and water solution or rubber lubricant.
13-4 BRAKES
Exploded View
BRAKES 13-5
Exploded View
Torque
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
G: Apply grease.
HG: Apply high-temperature grease.
13-6 BRAKES
Specifications

Brake Fluid
Type DOT3 – – –
Fluid Level Between upper and lower level lines – – –
Brake Pedal
Brake Pedal Free Play 2 ∼ 10 mm (0.08 ∼ 0.39 in.) – – –
Brake Drums
Brake Drum Inside Diameter 180.000 ∼ 180.160 mm (7.0866 ∼ 7.0929 in.) 180.75 mm
(7.116 in.)
Brake Panel Assemblies
Brake Shoe Lining Thickness 4.5 mm (0.18 in.) 1.0 mm (0.04 in.)
Parking Brake Lever and Cables
Parking Brake Lever Travel 8 ∼ 12 notches (clicks) at 200 N (20 kgf, 44 lb) – – –
BRAKES 13-7
Special Tools
Rotor Puller, M16/M18/M20/M22 × 1.5: Brake Drum Holder:
57001-1216 57001-1325
Brake Drum Remover: Brake Drum Remover Nuts:

57001-1260 57001-1326
Brake Drum Pusher, M18 × 1.5:

57001-1261
13-8 BRAKES
Brake Fluid
Brake Fluid Recommendation
Use extra heavy-duty brake fluid only from a container
marked DOT3.
Recommended Brake Fluid
Type: DOT3
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
diately.
Brake Fluid Level Inspection

• Refer to the Brake Fluid Level Inspection in the Periodic
Brake Fluid Changing
• Refer to the Brake Fluid Changing in the Periodic Main-
tenance chapter.
BRAKES 13-9
Brake Fluid
Brake Line Air Bleeding
• Remove the rubber cover.
• Check that there is plenty of fluid in the reservoir.
NOTE
○The fluid level must be checked several times during the
bleeding operation and replenished as necessary. If the
fluid in the reservoir runs completely out any time dur-
ing bleeding, the bleeding operation must be done over
again from the beginning since air will have entered the
line.
• With the reservoir cap off, slowly pump the brake pedal
several times until no air bubbles can be seen rising up
through the fluid from the holes at the bottom of the reser-
voir. This bleeds the air from the master cylinder end of
the line.
• 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.
• Pump the brake pedal [A] a few times until it becomes

hard to pump. Hold the pedal in the down position.
Quickly open (turn counterclockwise) and close the bleed
valve. Then release the pedal. Repeat this operation
until no more air can be seen coming out into the plastic
hose.
1. Hold brake pedal applied.
2. Quickly open and close bleed valve.
3. Release brake pedal.
• Tighten:
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Repeat the previous step for each wheel.
• level in thebleeding
When air is finished, add fluid up to the upper
reservoir.
• Apply the brake forcefully for a few seconds, and check
for fluid leakage around the fittings.
• Follow the procedure below to install the brake fluid reser-

voir cap correctly.
○First, tighten the brake fluid reservoir cap [B] clockwise
[C] by hand until the resistance is felt fully; then, tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir [A] body.
13-10 BRAKES
Brake Pedal and Master Cylinder
Brake Pedal Free Play Adjustment
• Refer to the Brake Pedal Free Play Adjustment in the Pe-
Master Cylinder Removal
• Remove:
Brake Hose Banjo Bolts [A]
Brake Pipe Nipple [B] (unscrew)
• Immediately wipe up any brake fluid that spills.
NOTICE
diately.
• 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.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
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-
Brake Hose and Pipe Replacement
• Refer to the Brake Hose and Pipe Replacement in the
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.
• The brake drums are press-fitted on the axles. Use the

brake drum remover set and rotor puller (special tools) to
remove the drums.
○Mount the brake drum remover on the drum studs with
the remover nuts and washers (parts in the remover set).
Special Tools - Rotor Puller, M16/M18/M20/M22 × 1.5 [A]:
57001-1216
Brake Drum Remover [B]: 57001-1260
Brake Drum Remover Nuts [C]: 57001-1326
Washers [D] (57001-1260)
○Do not remove the drum bolts. If a drum bolt is damaged,
replace the drum.
Brake Drum Installation
• Apply lithium grease (NLGI Grade No.2) to the brake drum
grease seal lips [A] and inside [B] of the drum as shown
in the figure.
Grease Seal [C]
Brake Drum [D]
• Install:
Collar [A] (Rear Brake only)
Brake Drum
13-14 BRAKES
Brake Drums
• Mount the brake drum holder [A] securely on the drum

studs with the wheel nuts.
Special Tool - Brake Drum Holder: 57001-1325
• Using the brake drum pusher [B], and tighten it until the
pusher stops.
Special Tool - Brake Drum Pusher, M18 × 1.5: 57001-1261
• And
nut.
then remove the pusher, install the washer and axle
• 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)
• Insert a new cotter pin [A].

NOTE
○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle shaft, tighten
the nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut [B].

WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
Brake Drum Wear

• Refer to the Brake Wear Inspection in the Periodic Main-
tenance chapter.
BRAKES 13-15
Brake Panel Removal
• Remove:
Brake Drum (see Brake Drum Removal)
Brake Pipe Nipple [A]
○Immediately wipe up any brake fluid that spills.
NOTICE
diately.
Loosen the brake wheel cylinder mounting bolts [B] for
the cylinder removal.
Remove the following for the brake panel assembly [A]
removal.
Brake Panel Mounting Bolts [B]
Brake Panel Assembly
• 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 the collar [E] on the rear brake panel.

13-16 BRAKES
• Remove the following for the rear brake panel removal.

Cotter Pin [A]
Clevis Pin [B]
Parking Brake Lever Linkage [C]
• Remove:
Brake Panel Mounting Bolts [A]
Brake Panel [B]
Brake Panel Installation

• Set the brake shoe clearance adjuster so that the drum
can be re-installed on the panel assembly.
○Front brake; turn one of the wheel cylinder ends [A] while
pushing it in. Keep the other end [B] from turning until both
the ends of the pistons are back in the cylinder completely.
○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
• Apply lithium grease (NLGI Grade No.2):

Brake Panel Seating Surface
Brake Panel Mounting Bolts
• Tighten:
Torque - Wheel Cylinder Mounting Bolts: 10.3 N·m (1.1
kgf·m, 91 in·lb)
Wheel Cylinder Mounting Nuts: 7.4 N·m (0.75
kgf·m, 65 in·lb)
Brake Panel Mounting Bolts: 44.1 N·m (4.5 kgf·m,
33 ft·lb)
• Grease [A]:
Brake Panel and Brake Shoe Contact Points
Wheel Cylinder Piston Ends
Brake Shoe Anchor Ends
• Grease (rear brake only) [B]:
Shoe Clearance Adjuster Pivots
Shoe Clearance Adjuster and Shoe Contact Points
• Bleed the brake line after drum installation.

• Check the brake system to be sure there is adequate
braking power. Also be sure there is no brake drag, or
fluid leakage.
WARNING
After servicing, it takes several applications of the
brake pedal before the brake shoes contact the
drum, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the vehicle until a
firm brake pedal is obtained by pumping the pedal
until the shoes are against the drum.
• Adjust:
Parking Brake Lever Travel Adjustment (see Parking
Brake Lever Travel Adjustment in the Periodic Mainte-
nance chapter)
13-18 BRAKES
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.
Wheel 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 the
cylinder.
• Inspect the cups.
If a cup is worn, damaged, softened (rotted), or swollen,
replace the cylinder.
If fluid leakage is noted at the dust covers, the cylinder
should be replaced to renew the cup.
• Check the dust covers for damage.
If they are damaged, replace the cylinder.
• Check the spring for any damage.
If the spring is damaged, replace the cylinder.
• Front brake only: Check the brake shoe clearance ad-
juster for damage.
If it shows any damage, replace the cylinder.
Dust Cover [A]
Piston [B]
Cup [C]
Shoe Clearance Adjuster (Front) [D]
Spring (Rear) [E]
Brake Shoe Lining Wear
• Refer to the Brake Wear Inspection in the Periodic Main-
tenance chapter.
BRAKES 13-19
Brake Shoe Spring Inspection
• Visually inspect the brake shoe springs [A] for breaks or
distortion.
If the springs are damaged in any way, replace them.
13-20 BRAKES
Parking Brake Lever and Cables
Parking Brake Lever Travel Adjustment
• Refer to the Parking Brake Lever and Cables in the Peri-
Parking Brake Cable Lubrication
• Whenever the parking brake cables are removed, or in
accordance with the Periodic Maintenance Chart in the
Periodic Maintenance chapter lubricate the cable.
• Refer to the the General Lubrication in the Periodic Main-
tenance chapter.
Parking Brake Cable Inspection
If the cable does not move freely after lubricating, or if the
cable is frayed, or if the cable housing is kinked, replace
the cable.
SUSPENSION 14-1
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
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.
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 the strut mounting nuts [A].
• Remove the strut [A] from the steering knuckle [B].

Front [C]
Strut (Front Shock Absorber) Installation

• Insert the strut to the steering knuckle [A] while aligning
the notch [B] on the strut with the clamp bolt hole [C] on
the steering knuckle.
• Replace the strut mounting nuts with new ones.
• Tighten:
Torque - Strut Mounting Nuts: 44 N·m (4.5 kgf·m, 32 ft·lb)
Strut Clamp Nuts: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
SUSPENSION 14-5

NOTE
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
the nearest hole.
Strut Spring Replacement

In addition to the standard springs, hard springs are avail-
able.
The hard springs stiffen the strut action and accelerate
the rebound damping.
• Remove the strut (see Strut (Front Shock Absorber) Re-
moval).
• Hold the large washer [A] in a vise [B].
• Remove:
Locknut [C] and Small Washer
Large Washer
• Remove:
Holder [A]
Thrust Plate [B]
Dust Seal
Thrust Washer
Upper Spring Seat [C]
Dust Cover [D]
Spring [E]
•○Install the replaced spring.

Fit the spring end [A] to the bulge [B] in the lower spring
seat [C].
14-6 SUSPENSION
• Install:
Dust Cover [A]
Upper Spring Seat [B]
○Fit the spring end to the bulge [C] in the dust cover and
upper spring seat.
• Apply grease to the upper and lower side on the following

parts, and install them.
Dust Seal [A]
Thrust Washer [B]
○Face the projection on the thrust washer downward.
• Install:
Holder [A]
Large Washer [B]
Small Washer [C]
Locknut [D]
○Push down the holder, and tighten the locknut.
Torque - Strut Locknuts: 50 N·m (5.1 kgf·m, 37 ft·lb)
Rear Shock Absorber Removal

• Remove:
Rear Wheel (see Wheel Removal in the Wheels/Tires
chapter)
Rear Shock Absorber Mounting Bolts and Nuts [A] (while
moving the frame up or down with a jack)
Rear Shock Absorber [B]
Rear Shock Absorber Installation

• Install the rear wheel temporarily and ground it to load the
suspension.
• Replace
ones.
the rear shock absorber mounting nuts with new
• Tighten:
Torque - Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
SUSPENSION 14-7
Shock Absorber Inspection
• Visually
tion.
inspect the shock absorber for breaks or distor-
If the shock absorber is damaged in any way, replace it.

• Check for oil leakage at the shock absorber damper unit.
If oil leakage is noted, the shock absorber should be re-
placed to renew the oil seal.
• Visually inspect the rubber bushings in the upper and/or
lower mountings of the rear shock absorber.
If they are worn, cracked, hardened, or otherwise dam-
aged, replace them with new ones.
14-8 SUSPENSION
Front Suspension Arms
Front Suspension Arm Removal
• Remove:
Front Wheel (see Wheel Removal in the Wheels/Tires
chapter)
Front Guard (see Front Guard Removal in the Frame
chapter)
• Hold the front brake drum and panel assembly in position.
• Remove the front suspension arm pivot bolts [A].
• 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].
Front Suspension Arm Installation

• Clean the tapered portion of the front suspension arm joint
and the tapered hole of the suspension arm, or the tapers
will not fit snugly.
• Apply grease to the sealing surface [A] of the front sus-
pension arm joint boot.
• When the front suspension arm pivot bolts are tightened,
install the arm joint to the suspension arm to position the
arm within its operating angle.
• Tighten:
Torque - Front Suspension Arm Pivot Bolts: 98 N·m (10.0
Front Suspension Arm Joint Nut: 78 N·m (8.0
kgf·m, 58 ft·lb)

NOTE
the nearest hole.
SUSPENSION 14-9
Front Suspension Arms
Front Suspension Arm Inspection

• Visually inspect the front suspension arm for breaks or
distortion.
If the front suspension arm is damaged in any way, re-
place it.
• Check the rubber bushings in the pivots.
Replace any bushings that are worn, cracked, hardened,
or otherwise damaged.
14-10 SUSPENSION
Leaf Springs and Dampers
Leaf Spring Removal
• Remove the rear wheel (see Wheel Removal in the
Wheels/Tires chapter).
• Hold the rear braket drum and panel assembly in position.
•○Immediately
Free the brake hose [A], pipe and cable from leaf spring.
wipe up any brake fluid that spills.
NOTICE
diately.
• 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]
Leaf Spring Installation

• When installing the rubber bushings to the leaf spring,
lubricate them with a soap and water solution.
NOTICE
Do not use engine oil or petroleum distillates to lu-
bricate the bushings because they will deteriorate
the rubber.
• Install the rear wheel temporarily and ground it to load the

suspension during the mounting nut tightening.
• Tighten:
Torque - Leaf Spring Mounting Nuts (Front): 98 N·m (10.0
Leaf Spring Mounting Nuts (Rear): 59 N·m (6.0
kgf·m, 44 ft·lb)
Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
SUSPENSION 14-11
Leaf Springs and Dampers
• Replace
ones.
the damper bracket mounting nuts with new
• Tighten the damper bracket mounting nuts in the order as

Front [A]
Outside [B]
Torque - Damper Bracket Mounting Nuts:
First: 20 N·m (2.0 kgf·m, 15 ft·lb)
Second: 44 N·m (4.5 kgf·m, 32 ft·lb)
Final: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Apply brake fluid to the brake pipe nipple threads.
• Tighten:
Torque - Brake Pipe Nipples: 17.7 N·m (1.8 kgf·m, 13 ft·lb)
• Bleed the brake line (see Brake Line Air Bleeding in the
Brakes chapter).
Leaf Spring Inspection
• Visually inspect the leaf spring for breaks or distortion.
If the leaf spring is damaged in any way, replace it.
• Check the rubber bushings in the mounts and the damper.
Replace any bushings or damper that are worn, cracked,
hardened, or otherwise damaged.
STEERING 15-1
Steering
Table of Contents
Exploded View................................... 15-2 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
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.
15-4 STEERING
Specifications

Steering Wheel
Steering Wheel Free Play 0 ∼ 20 mm (0 ∼ 0.79 in.) – – –
Steering Gear Assembly
Tie-Rod Length 43.5 mm (1.71 in.) – – –
(distance between boot end and locknut)
STEERING 15-5
Special Tools
Outside Circlip Pliers: Knuckle Joint Remover:
57001-144 57001-1619
Bearing Driver Set: Knuckle Joint Driver:

57001-1129 57001-1640
15-6 STEERING
Steering Wheel and Main Shaft Assembly
Steering Wheel Position Adjustment
• Loosen the steering shaft mounting nuts [A].
• Adjust the steering wheel position.
• Tighten the main shaft bracket mounting nuts securely.
Steering Wheel Free Play Inspection

• Refer to the Steering Inspection in the Periodic Mainte-
nance chapter.
Steering Wheel Centering
• Test ride the vehicle.
If the steering wheel is not straight when the vehicle is
traveling in a straight line, do the following.
• Check the tie-rod length and adjust it if necessary.
• Remove the wheel cap and horn switch (KAF620M9 ∼
MC/N9/P9 ∼ PC, see Steering Wheel and Steering Shaft
Removal).
• Remove the wheel cover (KAF620MD ∼/PD ∼, see Steer-
ing Wheel and Steering Shaft Removal).
• Loosen the steering wheel mounting nut [A].

• stop it without
Push the vehicle in a straight line with no one aboard, and
turning the steering wheel.
• Install:
Remount the steering wheel so that it is straight ahead.
• Spring Washer [B] (KAF620M9 ∼ MC/N9/P9 ∼ PC)
Washer [C] (KAF620MD ∼/PD ∼)
[D] KAF620M9 ∼ MC/N9/P9 ∼ PC
• Tighten:
Torque - Steering Wheel Mounting Nut: 52 N·m (5.3 kgf·m,
38 ft·lb)
• Install:
Horn Switch and Wheel Cap (KAF620M9 ∼ MC/N9/P9 ∼
PC, see Steering Wheel and Steering Shaft Installation)
Wheel Cover (KAF620MD ∼/PD ∼, see Steering Wheel
and Steering Shaft Installation)
• Be sure to register the EPS neutral position (see EPS
Neutral Position Registration).
STEERING 15-7
Steering Wheel and Steering Shaft Removal
(KAF620M9 ∼ MC/N9/P9 ∼ PC)
• Remove the battery (–) cable from the battery (see Battery
Removal in the Electrical System chapter).
• Remove
follows.
the wheel cap together with the horn switch as
○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.
• When removing the horn switch, unlock the stoppers [A].
• Remove:
Steering Wheel Mounting Nut [A] and Spring Washer
Steering Wheel
• Cut the bands [A].

• Disconnect the horn switch and connector [B].
15-8 STEERING
• Remove:
Screws [A] and Holder
Horn Switch Contact [B]
(KAF620M/N)
• Remove:
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 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
• 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-
• Adjust the following items.

Steering Wheel Position (see Steering Wheel Position
Adjustment)
Steering Wheel Centering (see Steering Wheel Center-
ing)
• Tighten:
38 ft·lb)
•○Install the horn switch [A] as follows.

Fit the front stoppers [B] in the recesses [C] of the steering
wheel.
○Fit the rear stopper [A] in the recess of the steering wheel
and push the rear part until sound click.
STEERING 15-11
• 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.
Steering Wheel and Steering Shaft Removal

(KAF620MD ∼/PD ∼)
• Clear the hook portions [A] from the steering wheel to
remove the wheel cover [B].
• Remove the wheel cover.
• Remove:
Steering Wheel Mounting Nut [A] and Washer [B]
Steering Wheel
• Remove the washer [A].
(KAF620M)
• Remove:
15-12 STEERING
• 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 Wheel and Steering Shaft Installation

(KAF620MD ∼/PD ∼)
• Apply grease to the dust cover lips [A].
(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:
15 ft·lb)
STEERING 15-13
(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)
• Install the washer [A].
• Mount
ily.

Adjustment)
ing)
• Replace the steering wheel mounting nut with a new one.
• Tighten:
38 ft·lb)
• Insert the hook portions [A] into the holes [B] of the steer-
ing wheel.
15-14 STEERING
Steering Gear Assembly Removal
• Remove:
Front Wheels (see Wheel Removal in the Wheels/Tires
chapter)
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].
• Remove the rubber dumpers [A].

STEERING 15-15
• Remove the mounting bolts [A] of the water pipe.
• Remove the universal joint clamp bolt [A].

If the clamp bolt becomes hard to turn, search the posi-
tion that it can be easily turned while turning the steering
wheel slowly.
• Pull out the rubber boot [B] upward temporary.
• 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].
• Remove the steering gear assembly [A] from the vehicle

left side [B].
Steering Gear Assembly Installation

• Adjust the following items if necessary.
Steering Gear Preload (see Steering Gear Preload Ad-
justment)
Tie-Rod Length (see Tie-Rod Length Adjustment)
• Clean the tapered portion of the tie-rod end joint and the
tapered hole of the steering knuckle, or the tapers will not
fit snugly.
• Apply grease to the sealing surface [A] of the tie-rod end
joint boot.
15-16 STEERING
• 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
Torque - Universal Joint Clamp Bolt: 20 N·m (2.0 kgf·m, 15

ft·lb)
[H] KAF620M9 ∼ MC/N9
[I] KAF620MD ∼
• 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)
NOTE
the nearest hole.
STEERING 15-17

• ment inthe
Check toe-in of the front wheels (see Toe-in Adjust-
the Wheels/Tires chapter).
• Neutral Position
Be sure to register the EPS neutral position (see EPS
Registration).
Steering Gear Preload Adjustment

• Tighten the rack guide spring cap [B] to 12.3 N·m (1.25
kgf·m, 109 in·lb) of torque.
• Back off the cap 40 ∼ 50°.
• Tighten the locknut while preventing the cap from turning.
Torque - Rack Guide Spring Cap Locknut: 39 N·m (4.0
kgf·m, 29 ft·lb)
Pinion [C]
Rack [D]
Rack Guide [E]
Spring [F]
Tie-Rod Length Adjustment

• Refer
ter.
to the Toe-in Adjustment in the Wheels/Tires chap-
Tie-Rod Length [A]
Steering Joint Dust Boot Inspection

• Refer to the Steering Joint Dust Boot Inspection in the
15-18 STEERING
Steering Knuckles
Steering Knuckle Removal
• Remove:
Front Brake Panel Assembly (see Brake Panel Assy Re-
moval in the Brakes chapter)
Cotter Pin
Tie-Rod End Nut [A]
Tie-Rod End [B] from Steering Knuckle
○Remove the tie-rod end from the steering knuckle, using
a suitable joint remover (see Steering Gear Assembly Re-
moval).
NOTICE
Do not loosen the tie-rod end locknuts [C], or the
toe-in of the front wheels will be changed.
• 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].
Steering Knuckle Installation

• Using a cleaning fluid, clean off any oil or dirt on the ta-
pered portions of the front suspension arm joint and the
tie-rod end joint, and the tapered holes of the steering
knuckle and the front suspension arm. Then dry them
with a clean cloth.
• Apply grease to the following portions.
Axle Bearing Grease Seal Lips
Front Suspension Arm Joint Boot Sealing Surfaces [A]
• Tighten:
Torque - Strut Clamp Nuts: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
Front Suspension Arm Joint Nuts: 78 N·m (8.0
kgf·m, 58 ft·lb)
Tie-Rod End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
STEERING 15-19
Steering Knuckles

NOTE
the nearest hole.

• ment inthe
Check toe-in of the front wheels (see Toe-in Adjust-
the Wheels/Tires chapter).
• EPS Neutral
Be sure to register the neutral position of the EPS (see
Position Registration).
Knuckle Bearing Removal

• Remove:
Steering Knuckle (see Steering Knuckle Removal)
Grease Seal [A]
• Drive the bearing [A] out using a suitable bearing driver

from the bearing driver set.
Special Tool - Bearing Driver Set: 57001-1129
Knuckle Bearing Installation

• Press in the bearing until it is bottomed.
Special Tool - Bearing Driver Set [A]: 57001-1129
• Replace the grease seal with a new one.
15-20 STEERING
Steering Knuckles
Knuckle Joint Removal
• Remove:
Steering Knuckle (see Steering Knuckle Removal)
Circlip [A]
• Remove the knuckle joint [A] using a press.

Special Tool - Knuckle Joint Remover [B]: 57001-1619
○First,press the knuckle joint until the remover end [C]
touches the knuckle.
○Second, move the remover [A] so that its center align with
the center of the knuckle joint.
○Press the knuckle joint, and remove it.
Knuckle Joint Installation

• Press the knuckle joint [A] until it is bottomed.
Special Tool - Knuckle Joint Driver [B]: 57001-1640
• Replace the circlip with a new one.
STEERING 15-21
EPS (Electric Power Steering) System (KAF620M/N)
Parts Location
EPS Warning Indicator Light (LED) [A]
EPS Motor [A]

[B] KAF620M9 ∼ MC/N9
[C] KAF620MD ∼
EPS Torque Sensor [A]

EPS Unit [B] (with EPS Motor and EPS Torque Sensor)
EPS ECU [A]

15-22 STEERING
Speed Sensor [A]
EPS Self-diagnosis System Connector [A]

EPS Fuse Box 2 (EPS Fuse 7.5 A ) [B]
EPS Fuse Box 1 (EPS Fuse 40 A ) [C]
STEERING 15-23
EPS System Wiring Diagram (KAF620M9 ∼ MA/N9)
1. EPS ECU 8. EPS Fuse 7.5 A

2. EPS Fuse 40 A 9. Oil Pressure Warning Indicator Light
3. EPS Motor 10. Ignition Switch
4. EPS Torque Sensor 11. Battery 12 V
5. EPS Self-diagnosis System Connector 12. Main Fuse 30 A
6. Speed Sensor 13. Fuse Box 1
7. EPS Warning Indicator Light (LED) 14. Oil Pressure Switch
○Color Codes:
BK: Black P: Pink
BL: Blue R: Red
BR: Brown W: White
G: Green Y: Yellow
15-24 STEERING
EPS System Wiring Diagram (KAF620MB ∼)
1. EPS ECU 9. Oil Pressure Warning Indicator Light

2. EPS Fuse 40 A 10. Ignition Switch
3. EPS Motor 11. Battery 12 V
4. EPS Torque Sensor 12. Main Fuse 30 A
5. EPS Self-diagnosis System Connector 13. Fuse Box 1
6. Speed Sensor 14. Oil Pressure Switch
7. EPS Warning Indicator Light (LED) 15. Diodes
8. EPS Fuse 7.5 A 16. EPS ECU Relay
○Color Codes:
BK: Black P: Pink
BL: Blue R: Red
BR: Brown W: White
G: Green Y: Yellow
STEERING 15-25
Terminal Names
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 System Servicing Precautions
There are number of important precautions that should be
followed servicing the EPS system.
○The EPS system operates while running the engine.

○This EPS system is designed to be used with a 12 V bat-
tery as its power source. Do not use any other battery
except for a 12 V battery as a power source.
○Do not reverse the battery cable connections. This will
damage the EPS ECU.
○To prevent damage to the EPS system parts, do not dis-
connect the battery cables or any other electrical connec-
tions when the ignition switch ON or while the engine is
running.
○Do not short the cables that are directly connected to the
battery positive (+) terminal to the chassis ground.
○Do not turn the ignition switch ON while any of the EPS
electrical connectors are disconnected. The EPS ECU
memorizes service codes.
○Do not spray water on the electrical system parts, EPS
system parts, connectors, leads and wiring.
○If a transceiver is installed on the vehicle, make sure that
operation of the EPS system is not influenced by electric
wave radiated from the antenna. Locate the antenna as
far as possible away from the EPS ECU.
○Whenever the electrical connections of the EPS system

are to be disconnected, first turn the ignition switch OFF.
Conversely, make sure that all the electrical connections
of the EPS system are firmly reconnected before turning
on the ignition switch.
○When reconnecting the connector, connect these connec-
tors securely until they click [A].
○The EPS system parts should never be struck sharply, as

with a hummer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○The EPS system parts can not be disassembled. Even if
a fault is found, do not try to disassemble and repair the
EPS system parts, replace it.
○With the front wheel lifted from the ground, do not move
the front wheel quickly. An abnormal voltage is generated
and the EPS ECU may be damaged.
○Using a fully charged battery. If the power supply voltage
of the EPS ECU becomes 10 V or less, EPS system does
not operate correctly.
STEERING 15-27
○There are 40 A and 7.5 A fuses for the EPS system. If
the fuse is blown, the EPS system does not operate. In
this case, the EPS warning indicator light (LED) does not
light up and even if engine is started. Replace the fuse.
WARNING
When replacing the 40 A fuse, first disconnect the
battery cables to avoid electrical shock.
○If the EPS system fuses are blown frequently, inspect the
EPS system parts.
○If the EPS ECU was replaced, be sure to register the EPS
neutral position (see EPS Neutral Position Registration).
The EPS system can not function until the neutral position
is registered in the new EPS ECU. In this case, the EPS
warning indicator light (LED) blinks immediately after en-
gine starts.
○If the following parts were removed or replaced, be sure
to register the neutral position of the EPS (see EPS Neu-
tral Position Registration). If the neutral position does not
register, EPS system does not operate correctly.
EPS Unit
Upper and Lower Universal Joints
Steering Knuckles
○Do not loosen the following bolts and nuts except repair
work. If the following bolts and nuts were loosened, be
sure to register the EPS neutral position (see EPS Neu-
tral Position Registration). If the neutral position does not
register, EPS system does not operate correctly.
Steering Gear Assembly Bracket Bolts
Tie-Rod End Nuts
Universal Joint Clamp Bolts
EPS Unit Mounting Bolts
○Before delivering the vehicle to the customer, be sure to
erase any service codes which might be stored in the EPS
ECU. Using the self-diagnosis function, confirm that the
EPS warning indicator light (LED) lights up (This shows
that there is no service code in the EPS ECU.).
EPS System Troubleshooting Outline
The EPS ECU is equipped with a self-diagnosis function.
When an abnormality in the EPS system occurs, the EPS
ECU lights the EPS warning indicator light (LED) [A] to alert
the rider. In addition, the condition of the problem is stored
in the memory of the EPS ECU as service codes and in
the self-diagnosis mode, the service code is indicated by
the number of times the EPS warning indicator light (LED)
blinks.
15-28 STEERING
If due to a malfunction, the EPS warning indicator light
(LED) remains lit, try to understand the background of the
trouble before starting the repair work. First ask the rider
about the conditions [A] of the trouble, and then start to ex-
amine the cause [B] of the trouble. Do not rely solely on the
self-diagnosis function, use common sense; for example,
check the connections of the connector.
If the problem is with the following parts, the EPS ECU

can not recognize these problem. Therefore, EPS warning
indicator light (LED) does not light up, and service code is
not indicated.
EPS Warning Indicator Light (LED)
EPS ECU Power Source Wiring and Ground Wiring
Speed Sensor
When the repair has been done, the EPS warning indi-
cator light (LED) lights up immediately after engine starts,
and goes off after 1 second. This shows that EPS system is
normal. But, service codes detected once by the EPS ECU
will be memorized in the EPS ECU. Therefore, after main-
tenance work ends, be sure to erase the service codes with
service code erase mode. Do not erase the service codes
during troubleshooting. Wait until all the checks and repair
work are finished to prevent duplication of previous service
codes and unnecessary maintenance work. Before eras-
ing the service codes, record them as problem history. The
problem history can be referred when solving unstable trou-
ble.
Even when the EPS system is operating normally, the
EPS warning indicator light (LED) may light up under strong
electrical interference. If the indicator light lights up, turn the
ignition switch OFF and then erase the service code.
Much of the EPS system troubleshooting work consists of
confirming continuity of the wiring. The EPS system parts
are assembled and adjusted by the manufacturer, so there
is no need to disassemble or repair them. Replace them as
an assembly.
The basic troubleshooting procedures and precautions
are listed below.
• Using a fully charged battery. A fully charged battery is a
must for conducting reliable self-diagnosis function.
• Measure coil winding resistance when the EPS system
part is cold (at room temperature).
• Check wiring and connections from the EPS ECU con-
nector to the suspected faulty EPS system part, using a
digital meter.
STEERING 15-29
• Visually inspect the wiring for signs of burning or fraying.

If any wiring is poor, replace the damaged wiring.
• Pull each connector [A] apart and inspect it for corrosion,
dirt and damage.
is damaged, replace it.
is suspected of being problem.
○Connect a digital meter between the ends of the leads.
○Set a digital meter to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Re-
place the main harness [B] if necessary.
• Narrow down suspicious parts and close in on the faulty

EPS system part by repeating the continuity tests.
If no abnormality is found in the wiring or connectors, the
EPS system parts are the next likely suspects. Check
each part one by one.
If an abnormality is found, replace the affected EPS sys-
tem part.
If all the parts and wirings are good, be sure to inspect the
power supply voltage of the EPS ECU.
If the power supply voltage is good, replace the EPS ECU.
15-30 STEERING
EPS System Diagnosis Flow Chart
STEERING 15-31
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of condition
the rider is dissatisfied with.
○Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know-
ing this information may help you reproduce the problem in the shop.
○The following sample diagnosis sheet will help prevent you from overlooking any keys, so always
use it.
Sample Diagnosis Sheet
Rider name: Registration No. (license plate No.):
Year of initial registration: Model:
Engine No.: Frame No.:
Date problem occurred: Problem frequency:
Weather: Mileage:
□ Steering wheel is heavy.
□ Steering wheel is too light.
□ Steering wheel is unbalance.
□ Steering wheel is naturally turned to one side.
Phenomenon
□ When operating the steering wheel, make vibration or noise.
□ When operating the steering wheel, the headlight darkens.
□ EPS system does not operate.
□ Other
Engine conditions at
problem
□ At start-up □ After starting
Driving conditions □ At high-speed □ At low-speed
□ lights up immediately after engine starts, and goes off after 1 second.
EPS warning □ lights up immediately after engine starts, and stays on.
indicator light (LED) □ Blinks immediately after engine starts, and stays on.
conditions □ Does not light up.
□ Sometimes lights up.
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
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.

• Disconnect
Tilt up the front seat.
• the EPS self-diagnosis system connector [A].
• Connect an auxiliary lead [A] to the terminals of the EPS

self-diagnosis system connector [B] as shown.
Auxiliary Lead Connections:
BL Lead [C] ←→ BK/Y Lead [D]
○The BK/Y lead terminal is connected to the battery (–)
terminal.
• Start the engine.
• Count the blinks of the indicator light to read the service
code (see Service Code Reading).
NOTE
○Keep connections of the auxiliary lead until you finish
reading the service code.
○If there is no service code, the EPS warning indicator
light (LED) remains lit and service code is not indicated.
• Any of the following procedures ends the self-diagnosis

mode.
○When the ignition switch is turned OFF.
○When the auxiliary lead is disconnected from the termi-
nals of the EPS self-diagnosis system connector.
STEERING 15-33
Service Code Reading
○Service codes are shown by a series of long and short blinks of the EPS warning indicator light
(LED) as shown below.
○Read 10th digit and unit digit as the EPS warning indicator light (LED) blinks.
○The EPS ECU can memorize all the service codes except the service code 31.
○When there are plural service codes in the memory of the EPS ECU, the service codes are displayed
from the lowest number code in the ascending order. The display is repeated until the ignition switch
is turned OFF or the auxiliary lead is disconnected from the terminals of the EPS self-diagnosis
system connector.
○For example, if two problems occurred in the order of 32,12, the service codes are displayed from
the lowest number code in the order listed.
(12→32) → (12→32) →· · · (repeated)
Service Code Erasing

○The service code memorized in the EPS ECU can not be
erased even if the ignition switch is turned OFF or battery
cables are disconnected.
○Refer to the Service Code Erasing Procedure for the ser-
vice code erasure.
15-34 STEERING
Service Code Table
Service
EPS Warning Indicator Light (LED) Failure Parts Problems
Code
Power supply voltage from
11 –
ignition switch is abnormal.
Power supply voltage from

12 –
battery is abnormal.
EPS neutral position is

31 (1) –
unregistration.
32 Current sensor is trouble.
FET(Field Effect Transistor) for

33
EPS motor is trouble.
34 Internal relay is trouble.

EPS ECU
CPU (Central Processing Unit) is
35
trouble.
Direction distinction circuit for

36
EPS torque sensor is trouble.
Boosting transformer circuit is

37
trouble.
51 EPS torque sensor is trouble.

EPS Unit
61 EPS motor is trouble.
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
Self-diagnosis Flow Chart
15-36 STEERING
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.
goes off.
○Eighth, free the hands from the steering wheel after indi-
cator light goes off.
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
Service Code Erasing Flow Chart
15-38 STEERING
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-
○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 EPS warning indicator light (LED) remains lit or
blinks, 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.
lights up.
○Seventh, turn the steering wheel fully to the left and keep
it, after indicator light lights up.
goes off.
○Eighth, free the hands from the steering wheel after indi-
cator light goes off.
blinks two times. This blink shows that the service code
in the EPS ECU was erased.
If the EPS warning indicator light (LED) does not blink or
lights up, turn the ignition switch OFF and repeat from
fourth procedure again.
NOTE
○The service code erase is same procedure as until
eighth procedure.
STEERING 15-39
○Ninth, wait for 5 seconds after indicator light blinks two
times.
blinks three times. This blink shows that the EPS neutral
position was registered.
If the EPS warning indicator light (LED) does not blink,
turn the ignition switch OFF and repeat from fourth pro-
cedure again.
○Lastly, wait for 1 second or more after indicator light blinks
three times and turn the ignition switch OFF.
• Disconnect the auxiliary lead from the terminals of the

self-diagnosis system connector.
• Start the engine and confirm that the EPS warning indi-
cator light (LED) lights up for 1 second and goes off.
• Confirm the EPS operates correctly.
15-40 STEERING
EPS Neutral Position Registration Flow Chart
STEERING 15-41
Power Supply Voltage Abnormal (Service Code
11,12)
○The usable range of the power supply voltage is 10 V to
16 V.
• Check the charging condition (see Alternator Operation
Inspection in the Electrical System chapter).
If the charging condition is normal, check the power sup-
ply voltage (see EPS ECU Power Supply Voltage Inspec-
tion).
If the power supply voltage is good, but the problem still
exists, replace the EPS ECU (see EPS ECU Removal/In-
stallation).
EPS Neutral Position Unregistration (Service
Code 31)
○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.
• Register the EPS neutral position in the new EPS ECU
(see EPS Neutral Position Registration).
Current Sensor Inspection (Service Code 32)
○The current sensor is built in the EPS ECU [A]. So, the
current sensor itself can not be inspected.

• Disconnect the EPS ECU and EPS motor connectors.
• connectors.
Check the wiring for continuity between main harness

EPS ECU Connector [A] ←→
EPS Motor Connector [B]
R Lead [C]
BK Lead [D]
If the wiring is good, check the power supply voltage (see
EPS ECU Power Supply Voltage Inspection).
stallation).
15-42 STEERING
FET (Field Effect Transistor) Inspection (Service
Code 33)
○The FET is built in the EPS ECU [A]. So, the FET itself
can not be inspected.

• Check the wiring
Disconnect the EPS ECU and EPS motor connectors.
• connectors. for continuity between main harness

R Lead Terminal [C]
BK Lead Terminal [D]
stallation).
Internal Relay Inspection (Service Code 34)
○The relay function is included in the EPS ECU [A]. So, the
relay function can not be inspected.


R Lead Terminal [C]
stallation).
STEERING 15-43
CPU (Central Processing Unit) Inspection (Service
Code 35)
○The CPU is built in the EPS ECU [A]. So, the CPU itself
can not be inspected.
• Check the power supply voltage (see EPS ECU Power
Supply Voltage Inspection).
stallation).
Direction Distinction Circuit Inspection (Service

Code 36)
○The direction distinction circuit is built in the EPS ECU
[A]. So, the direction distinction circuit itself can not be
inspected.


R Lead Terminal [C]
stallation).
Boosting Transformer Circuit Inspection (Service
Code 37)
○The boosting transformer circuit is built in the EPS ECU
[A]. So, the boosting transformer circuit itself can not be
inspected.
15-44 STEERING


R Lead Terminal [C]
stallation).
EPS Torque Sensor Inspection (Service Code 51)
• Disconnect the EPS torque sensor connector [A].
• 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
If the reading is in specification, disconnect the EPS ECU
connectors and check the wiring for continuity between
main harness connectors.
EPS Torque Sensor Connector [B]
Y/BK Lead [C]
Y/R Lead [D]
BK/BL Lead [E]
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).
• Disconnect the EPS motor connector [A].
[C] KAF620MD ∼
15-46 STEERING
• EPS
Set a digital meter to the × 1Ω range and connect it to the
motor connector [A].
[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 reading is not infinity (∞) Ω, disconnect the EPS ECU

R Lead Terminal [C]
stallation).
EPS Warning Indicator Light (LED) Removal
• Remove:
Control Panel (see Control Panel Removal in the Frame
chapter)
Nut [A]
EPS Warning Indicator Light (LED) [B]
STEERING 15-47
EPS Warning Indicator Light (LED) Inspection
• Remove:
ment Removal in the Frame chapter).
• Disconnect the EPS warning indicator light (LED) lead
connectors.
R Lead [A]
BK/W Lead [B]
• Using two auxiliary leads, connect the 12 V battery [A] to

the EPS warning indicator light (LED) lead connectors as
follows.
EPS Warning Indicator Light (LED) Inspection
Connections:
Battery (+) Terminal → R Lead
Battery (–) Terminal → BK/W Lead
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 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
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].
• Disconnect the EPS ECU connectors [A].

STEERING 15-49
• Remove:
Right Glove Compartment (see Glove Compartment Re-
Screws [A]
EPS ECU [B] (with Cover)
• Remove the cover [A] from the EPS ECU.
EPS ECU Installation

• Check that the rubber dampers [A], collars [B] and wellnut
[C] are in place on the frame.
If the rubber dampers are damaged or deteriorated, re-
place them.
○When installing the rubber dampers, note the following.
○Install the two rubber dampers of the front side so that the
thin thickness side faces right side.
○Do not apply a soap and water solution or rubber lubri-
cant.
•○Install the cover [A] on the EPS ECU.

Install the cover so that open side faces left side.
• Insert the projections [B] of the EPS ECU to the rubber
dampers [C].
• Tighten the screws securely.
•○When installing the band to the cover, note the following.

Pass the band through four slits [A] of the cover.
○Bind the cover with the band securely.
If the EPS ECU was replaced, be sure to register the EPS
neutral position(see EPS Neutral Position Registration).
NOTE
○The EPS system can not function until the neutral posi-
tion is registered in the new EPS ECU.
15-50 STEERING
EPS ECU Power Supply Voltage Inspection
• Remove
Removal).
the band and open the cover (see EPS ECU
• Visually inspect the EPS ECU connectors [A].

If the connector is clogged with mud or dust, blow it off
with compressed air.
If the connectors are normal, check the terminals of the
EPS ECU connectors.
• Disconnect the EPS ECU connectors.
• Visually inspect the terminals of the EPS ECU connectors
(main harness and EPS ECU).
If the terminals of the main harness connectors are dam-
aged, replace the main harness.
If the terminals of the EPS ECU connectors are damaged,
replace the EPS ECU.
If the terminals are normal, measure the power supply
voltage of the EPS ECU.
NOTE
• Set a digital meter [A] to the DC 25 V range and connect
it to the main harness connectors [B].
EPS ECU Power Supply Voltage Inspection
Connections:
(I) Digital Meter (+) → W Lead Terminal [C]
Digital Meter (–) → Battery (–) Terminal
(II) Digital Meter (+) → BL/R Lead Terminal [D]
Digital Meter (–) → Battery (–) Terminal
Ignition Switch OFF:
Connection (I): Battery Voltage
Connection (II): 0 V
Engine Running:
Both Connections: Battery Voltage
If the reading is out of the specification, check the follow-

ing.
EPS Fuse 40 A (see Fuse Inspection)
EPS Fuse 7.5 A (see Fuse Inspection)
Oil Pressure Switch (see Switch Inspection in the Elec-
trical System chapter)
Oil Pressure Warning Indicator Light
Power Source Wiring and Ground Wiring (Refer to the
next wiring diagram.)
STEERING 15-51
EPS ECU Power Source Circuit
1. EPS ECU 6. Battery 12 V

2. EPS Fuse 40 A 7. Main Fuse 30 A
3. EPS Fuse 7.5 A 8. Fuse Box 2
4. Oil Pressure Warning Indicator Light 9. Oil Pressure Switch
5. Ignition Switch
EPS Motor Removal
NOTICE
Do not remove the EPS motor [A] from the EPS unit
since it has been adjusted and set with precision at
the factory.
[C] KAF620MD ∼
15-52 STEERING
EPS Torque Sensor Removal
NOTICE
Do not remove the EPS torque sensor [A] from the
EPS unit since it has been adjusted and set with
precision at the factory.
EPS Unit Removal

NOTICE
The EPS unit [A] has been adjusted and set with pre-
cision at the factory. Therefore, it should be han-
dled carefully, never struck sharply, as with a ham-
mer, or allowed to fall on a hard surface. Be careful
not to get water or mud on the EPS unit.
• Remove:
chapter)
Left Radiator Side Cover (see Radiator Side Cover Re-
• Disconnect:
Water Hoses [A]
• Remove the steering gear assembly bracket bolts [B] and
brackets [C].
• Remove the mounting bolts [A] of the water pipe.
• Remove the universal joint clamp bolt [A].

If the clamp bolt becomes hard to turn, search the posi-
tion that it can be easily turned while turning the steering
wheel slowly.
• Pull out the rubber boot [B] upward temporary.
STEERING 15-53
• 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)
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]
• Remove the EPS unit mounting bolts [A].

15-54 STEERING
• Remove the EPS unit [A] downward while pushing down

the brake pedal [B].
○Insert the lower shaft to the hole of the under cover and
avoid the upper shaft from the frame.
NOTICE
The EPS unit [A] has been adjusted and set with
precision at the factory. Do not try to disassemble
and repair the EPS unit.
[C] KAF620MD ∼
EPS Unit Installation

• Check that the rubber dampers [A] and upper and lower
collars [B] are in place on the frame.
If the rubber dampers are damaged or deteriorated, re-
place them.
○When installing the rubber dampers, note the following.
○Install the rubber dampers so that the thin thickness side
faces up.
○Do not apply a rubber lubricant.
• 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
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
• 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].
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
Torque - EPS Unit Mounting Bolts: 20 N·m (2.0 kgf·m, 15

ft·lb)
[H] KAF620M9 ∼ MC/N9
[I] KAF620MD ∼
• 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.
15 ft·lb)
• Install the washer [I]. (KAF620MD ∼)
[J] KAF620M9 ∼ MC/N9
15-56 STEERING
• Mount
ily.

Adjustment)
ing)
• Install the removed parts (see appropriate chapters).
Speed Sensor Removal/Installation
• Refer to the Speed Sensor Removal/Installation in the
Speed Sensor Inspection
• Refer to the Speed Sensor (Service Code 24) section in
the Fuel System (DFI) chapter.
If the speed sensor is normal, disconnect the EPS ECU
EPS ECU Connector [A] ←→ Speed Sensor Connector
[B]
P Lead Terminal [C]
If the wiring is good, check the EPS ECU for its power
supply voltage (see EPS ECU Power Supply Voltage In-
spection).
stallation).
EPS ECU Relay Removal/Installation
NOTICE

• from the tongue
Remove the EPS ECU relay [A] (BK/Y, W/Y, BR, W/BL)
and disconnect the connector.
• Installation is the reverse of removal
STEERING 15-57
EPS ECU Relay Inspection
• Remove:
EPS ECU Relay (see EPS ECU Relay Removal/instal-
lation)
• Connect a digital meter [A] and a 12 V battery [B] to the
relay [C] as shown.
Testing Relay
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 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].
• Disconnect the battery cables (see Battery Removal in the

Electrical System chapter).
• Lift up the EPS fuse box 1 [A] with rubber protector [B].
• Slide the rubber protector [A].

• Unlock the hooks to open the lids [B].
• Remove the terminal bolt [A] on both sides.
• Unlock the hook to lift up the lid [A].

• Pull the EPS fuse 40 A [B] straight out of the EPS fuse
box 1 [C].
STEERING 15-59
EPS Fuse 7.5 A Removal
• Tilt up the front seat.
• Unlock the hook to lift up the lid [A].
• 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.
16-4 FRAME
Exploded View
FRAME 16-5
Exploded View
Torque
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
9. CA Model
G: Apply grease.
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
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.
G: Apply grease.
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
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.
Seat Belt Removal

• Remove:
Seat Belt Mounting Bolts [A]
Seat Belts [B]
• Remove (Both Sides):

Seat Belt Buckle Mounting Bolts [A]
Seat Belt Buckles [B]
FRAME 16-11
Seat and Seat Belts
Seat Belt Installation
• Tighten:
Torque - Seat Belt Mounting Bolts: 34.3 N·m (3.5 kgf·m, 25
ft·lb)
Seat Belt Buckle Mounting Bolts: 34.3 N·m (3.5
kgf·m, 25 ft·lb)
16-12 FRAME
Control Panel
Control Panel Removal
• Remove:
ment Removal)
Band [A]
• Free the leads from the clamp [B].
• Disconnect:
Light Switch Lead Connector [C]
Oil Pressure Warning/DFI Warning Indicator Light Lead
Connector [D]
Water Temperature Warning/Parking Brake Indicator
Light Lead Connector [E]
Power Steering Warning Light Lead Connectors [F]
• Disconnect the horn

(KAF620MD ∼/PD ∼).
switch lead connectors [A]
• Remove the band [A].

• Hour Meter Lead Connectors [B]
Disconnect:
Fuel Gauge/Hour Meter Lead Connectors [C]

Ignition Switch Lead Connector [D]
Power Outlet Connector Lead Connectors [E]
[F] KAF620M9 ∼ MC/N9/P9 ∼ PC
[G] KAF620MD/PD ∼
FRAME 16-13
Control Panel
• Remove the steering wheel (see Steering Wheel and

Steering Shaft Removal in the Steering chapter).
• Remove
lars.
the control panel mounting screws [A] and col-
• Open the glove compartment covers [B].

• Remove the control panel [C].
Control Panel Installation

Run the harness, cables and leads correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
Glove Compartment Removal
• Remove:
Control Panel (see Control Panel Removal)
Screws [A]
Glove Compartment [B]
16-14 FRAME
Front Cargo Compartment
Front Cargo Hood Removal
• Tilt up the cargo hood [A].
• Remove:
Cargo Hood Mounting Bolts [B] and washers
Cargo Hood
Front Cargo Hood Installation

If the dampers [A] are removed from the front cargo hood
[B], install them as follows.
0 ∼ 5 mm (0 ∼ 0.20 in.) [C]
2 ∼ 5 mm (0.08 ∼ 0.20 in.) [D]

Contact the bracket [A] of the front cargo hood and the
boss [B] of the arm [C].
FRAME 16-15
Front Cargo Compartment
If the hook bracket was removed from the front cargo
hood, install it as follows.
○Tighten the bolts [A] while pushing the bracket [B] forward
[C].
Front Cargo Hood Cable Adjustment

Compartment Removal).
• Loosen the adjuster mounting nuts [A], and slides the ad-
juster as shown in the figure.
20.5 ∼ 21.5 mm (0.81 ∼ 0.85 in.) [B]
• Tighten the adjuster mounting nuts securely.
Front Cargo Compartment Removal

• Remove:
Front Fenders (see Front Fender Removal)
Coolant Reserve Tank (see Coolant Reserve Tank Re-
moval in the Cooling System chapter)
• Remove:
Screws [A] and Collars
• Remove:
Side Mounting Bolts [A] (Left and Right)
Front Cargo Compartment [B]
Front Cargo Compartment Installation

• Installation
parts size.
is the reverse of removal, note the following
Screws [A] [L = 16 mm (0.63 in.)] and Collars [L = 4 mm

(0.16 in.)]
Screws [B] [L = 22 mm (0.87 in.)] and Collars [L = 6 mm
(0.24 in.)]
Tapping Screw [C] [L = 16 mm (0.63 in.)] and Collar [L =
4 mm (0.16 in.)]
16-16 FRAME
Cargo Bed
Cargo Bed Removal
• Remove the rear fender assembly (see Rear Fender As-
sembly Removal).
• Open the clamps [A] and disconnect the tail/brake light
lead connectors [B] (left and right).
• Remove (Left and Right):
Bolts [C]
Tail/Brake Light Assemblies [D]
• Open the steal clamp on the cargo bed and free the lead.
• Unlock the hooks [A].

• to store. rear seat and push it toward the front seat back
Raise the

Snap Pins [A]
Cargo Bed Mounting Pins [B]
• Remove the cargo bed.
Cargo Bed Installation

Apply lithium grease (NLGI Grade No.2) to the cargo bed
mounting pins.
○Check that the following are in place on the cargo bed and
frame.
Cargo Bed Rubber Dampers [A]
Tail Gate Pivot Rubber Dampers (Left and Right)
• When the cargo bed is disassembled, note the following

when installing the plates and tail gate.
○Be sure the clearance [A] between the back end of the
carrier [B] and the bottom of the tail gate [C] is more than
2 mm (0.079 in.) as shown in the figure (left and right).
FRAME 16-17
Cargo Bed
○Be sure the clearance [A] between the plate end [B] and
the tail gate end [C] is less than 5 mm (0.197 in.) as shown
in the figure (left and right).
16-18 FRAME
Front and Rear Bars
Front Bar Removal
• Remove:
Front Bar Mounting Bolts [A] and Washers (Upper)
Front Bar Mounting Bolts [B] (Lower)
Front Bar [C]
Front Bar Installation

• Tighten:
Torque - Front Bar Mounting Bolts (Upper): 44 N·m (4.5
kgf·m, 32 ft·lb)
Front Bar Mounting Bolts (Lower): 98 N·m (10.0
• Install the front fenders (see Front Fender Installation).
Rear Bar Removal
• Rear Side Covers (see Rear Side Cover Removal)
Remove:
Rear Bar Mounting Bolts [A] and Washers (Upper)
• 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.
Cargo Bed Latch Position Adjustment

• Loosen the mounting bolts [A].
• the ellipse bolt
Reposition the latch to the suitable place by sliding within
holes.
• Retighten the mounting bolts.
NOTE
○Adjustment must be made on both sides.
16-20 FRAME
Guard
Front Guard Removal
• Remove:
Screws [A] and Collars (KAF620M9 ∼ MC/N9/P9 ∼ PC)
Front Guard Cover [B] (KAF620M9 ∼ MC/N9/P9 ∼ PC)

Front Guard Bolts [A] (Upper)
Front Guard Bolts [B] and Nuts (Lower)
• Remove the front guard [C].
[D] KAF620M9 ∼ MC/N9/P9 ∼ PC
FRAME 16-21
Fenders
Front Fender Removal
• Remove:
Rivets [B]
• Clear the hook portion [C] from the slot and remove the
front fender [D].
Front Fender Installation

○Check that the clip-nuts [A] are in place as shown in the
figure.
• 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]

(0.16 in.)]
Screw [B] [L = 22 mm (0.87 in.)] and Collar [L = 6 mm
(0.24 in.)]
Tapping Screw [C] [L = 20 mm (0.79 in.)] and Collar [L =
9.5 mm (0.37 in.)]
Quick Rivets [D]
Rear Fender Assembly Removal

• Remove:
Rear Fender [B]
16-22 FRAME
Fenders
• 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
• Remove:
Front Guard (see Front Guard Removal)
Screws [A] and Collars (Left and Right)
Bolts [B] and Washers (Left and Right)
• Disconnect the head light connecters [A] (Left and Right).

• Remove the front cover [B] with head lights assembly.
Front Cover Installation

Check that the clip-nuts [A] (left and right) are in place as
○Attach the rubber damper [A] of the bracket to the dent

[B] of the front cover.
Front Fender Inner Cover Removal

• Remove:
Front Fender (see Front Fender Removal)
Tapping Screw [A] and Collar
Quick Rivets [B]
Front Fender Inner Cover [C] (Middle)
16-24 FRAME
Covers
• Remove:
Tapping Screws [A] and Collars
Quick Rivets [B]
Front Fender Inner Cover [C] (Front)
• Remove:
Middle Cover (see Middle Cover Removal)
Screws [B]
Nut [C] and Collar
Quick Rivets [D]
Front Fender Inner Cover [E] (Rear)
Radiator Side Cover Removal

• Remove:
Tapping Screws [A]
Bolt [B]
• Remove the front guard mounting nut [C] temporary, and
remove the radiator side cover [D].
Front Side Cover Removal

• Remove:
Quick Rivets [B]
Front Side Cover [C]
Front Side Cover Installation

• Install
size.
the front side cover, note the following parts [A] [B]
Screw [A] [L = 16 mm (0.63 in.)] and Collar [L = 4 mm

(0.16 in.)]
(0.24 in.)]
Quick Rivets [C]
FRAME 16-25
Covers
Rear Side Cover Removal
• Remove:
Quick Rivets [B]
Rear Side Cover [C]
Rear Side Cover Installation

figure.
• Install:
(0.16 in.)]
(0.24 in.)]
Quick Rivets [C]
Middle Cover Removal

• Remove:
Quick Rivets [B]
Screw [C] and Collar
Middle Cover [D]
Middle Cover Installation

•○Install is the reverse of removal, note the following.
Check that the clip-nuts [A] are in place as shown in the
figure.
16-26 FRAME
Covers
Flap Cover Removal
• Remove:
Quick Rivets [B]
Flap Cover [C]
Flap and Flap Stay Removal

• Remove:
Rear Side Cover (see Rear Side Cover Removal)
Flap Cover (see Flap Cover Removal)
Screw [A] and Collar
Quick Rivet [B]
Flap [C]
• Remove:
Flap Stay Mounting Bolts [A]
Flap Stay [B]
Floor Center Panel Removal

• Remove:
Screws [A]
Quick Rivets [B]
Front Seat Lower Cover [C]
• Remove:
Bolts [A]
Throttle Pedal [B]
FRAME 16-27
Covers
• Remove:
Tapping Screws [A]
Floor Center Panel [B]
Floor Center Panel Installation

Install the bushing [A] so that the cut side [B] faces to the
throttle pedal.
16-28 FRAME
Rear End Subframe
Rear End Subframe Removal
• Remove:
stallation chapter)
Transmission Case (see Transmission Case Removal in
the Transmission chapter)
• Cut the band [A].
• Remove:
Rear End Subframe Mounting Bolts [B] and Nuts
Rear End Subframe [C]
Rear End Subframe Installation

• Replace
ones.
the rear end subframe mounting nuts with new
• 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
Exploded View
Torque
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
4 Oil Pressure Switch 9.8 1.0 87 in·lb SS
5 Spark Plugs 17 1.7 13
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.
SS: Apply silicone sealant.
Exploded View
Exploded View
Torque
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
Exploded View
Exploded View
1. KAF620M9 ∼ MC/N9/P9 ∼ PC
2. KAF620MD ∼/PD ∼
Specifications

Battery
Type Sealed Battery – – –
Model Name (CA) YTX20L-BS – – –
Capacity (US) 12 V 14 Ah – – –
(CA) 12 V 18 Ah – – –
Voltage (US) 12.6 V or more – – –
(CA) 12.8 V or more – – –
Gross Weight (US) 7.0 kg (15 lb) – – –
(CA) 6.3 kg (14 lb) – – –
Electrolyte Volume (US) 2.18 L (133 cu in.) – – –
(CA) 0.93 L (57 cu in.) – – –
Charging System
Type Three-phase AC – – –
Regulator/Rectifier Output Voltage 14.0 ∼ 15.0 V at 25°C (77°F) – – –
Alternator Output Voltage AC 45 V or more at 3 000 rpm – – –
Stator Coil Resistance 0.15 ∼ 0.23 Ω at 20°C (68°F) – – –
Ignition System
Spark Plug:
Type NGK BPR2ES – – –
Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) – – –
Ignition Coil Winding Resistance:
Primary Winding 1.9 ∼ 2.5 Ω at 20°C (68°F) – – –
Secondary Winding 10.4 ∼ 15.6 kΩ at 20°C (68°F) – – –
Ignition Coil Primary Peak Voltage 300 V or more – – –
Crankshaft Sensor Resistance 88 ∼ 132 Ω at 20°C (68°F) – – –
Crankshaft Sensor Peak Voltage 3.5 V or more – – –
Electric Starter System
Starter Motor:
Carbon Brush Length 15.5 mm (0.61 in.) 8.5 mm (0.33 in.)
Commutator Diameter 30 mm (1.18 in.) 29 mm (1.14 in.)
Switches and Sensors
Brake Light Switch Timing ON after 10 mm (0.39 in.) of pedal travel – – –
Water Temperature Sensor
In the text – – –
Resistance
Special Tools
Peak Voltage Adapter: Rotor Puller:
57001-1415 57001-1623
Needle Adapter Set: Rotor Holder:

57001-1457 57001-1727
Grip:
57001-1591
Wiring Diagram (KAF620M9/N9, MA)
Wiring Diagram (KAF620M9/N9, MA)
Wiring Diagram (KAF620MB ∼ MC)
Wiring Diagram (KAF620MB ∼ MC)
Wiring Diagram (KAF620MD)
Wiring Diagram (KAF620MD)
Wiring Diagram (KAF620ME)
Wiring Diagram (KAF620ME)
Wiring Diagram (KAF620P9/PA)
Wiring Diagram (KAF620P9/PA)
Wiring Diagram (KAF620PB ∼ PC)
Wiring Diagram (KAF620PB ∼ PC)
Wiring Diagram (KAF620PD)
Wiring Diagram (KAF620PD)
Wiring Diagram (KAF620PE)
Wiring Diagram (KAF620PE)
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 ∼
Hour Meter [A]

Ignition Switch [B]
Power Outlet Connector [C]
Fuel Gauge/Hour Meter [D]
[E] KAF620M9 ∼ MC/N9/P9 ∼ PC
[F] KAF620MD ∼/PD ∼
Horn [A]
Radiator Fan [B]
Brake Light Switch [C]
Parts Location
Fuel Pump [A]
Radiator Fan Breaker [B]
Battery [A]
Regulator/Rectifire [B]
EPS Self-diagnosis System Connector [A] (KAF620M/N)

Regulator/Rectifire [B]
ECU (Electronic Control Unit) [C]
Parking Brake Light Switch [D]
EPS Fuse 40 A [A] (KAF620M/N)

EPS Fuse 7.5 A [B] (KAF620M/N)
KDS Connector [C]
Fuse Box 1 [D]
Fuse Box 2 [E]
Radiator Fan Breaker [F]
Starter Circuit Relay [G]
ECU Relay [H]
Fuel Pump Relay [I]
Radiator Fan Relay [J]
Frame Ground Terminal [K]
Starter Relay [A] (KAF620ME/PE)
Parts Location
Water Temperature Sensor [A]
Alternator [A]
Crankshaft Sensor [B]
Oil Pressure Switch [C]
Spark Plug (Front) [A]

Ignition Coil #1 [B]
Engine Ground Terminal [C]
Starter Motor [D]
Ignition Coil #2 [E]
Spark Plug (Rear) [F]
Neutral Switch [A]

Speed Sensor [B]
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○Do not reverse the battery lead connections. This will
burn out the diodes in the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery cable or any other electrical connections when
the ignition switch is on, or while the engine is running.
○Because of the large amount of current, never keep the
main switch turned to the start position when the starter
motor will not turn over, or the current may burn out the
starter motor windings.
○Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was brought on by
some other item or items, they too must be repaired or
replaced, or the replacement part will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
leads and bad connections will affect electrical system
operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Color Codes:
BK: Black G: Green P: Pink
BL: Blue GY: Gray PU: Purple
BR: Brown LB: Light Blue R: Red
CH: Chocolate LG: Light Green W: White
DG: Dark Green O: Orange Y: Yellow
Electrical Wiring
Wiring Inspection
• Visually
etc.
inspect the wiring for signs of burning, fraying,
If any wiring is poor, replace the damaged wiring.

•Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
is damaged, replace it.
is suspected of being a problem.
○Measure the resistance between the ends of the leads.
If the resistance is not 0 Ω, the wire is defective. Replace
the lead or the wiring harness if necessary.
Battery
○In this model, two batteries are prepared.
Pre-charged Sealed Type Battery [A] (US Model)
Sealed Type Battery [A] (CA Model)
Battery Removal
• Turn off the ignition switch.
• Remove:
Quick Rivets [A]
Screws [B]
Battery Cover [C]
• Disconnect the battery negative (–) cable [A].

NOTICE
Be sure to disconnect the negative (–) cable first.
• Remove:
Battery Holder Nuts [B] and Holder Rods
Battery Holder [C]
• Slide the battery.

• Disconnect the battery positive (+) cable [A].
• Battery [B]
Remove:
Battery
Battery Installation
• Turn off the ignition switch.
• Check that the dampers [A] on the frame and battery
brackets [B] are properly in place.
• Put the battery on the frame.

• Put a lightthecoat
Connect positive (+) cable first.
• rosion. of grease on the terminal to prevent cor-
• Install the terminal cap on the positive terminal.

• Install: battery at the battery bracket.
Set the
• Battery Holder
Battery Holder Nuts and Holder Rods
• Tighten:
Torque - Battery Holder Nuts: 2.0 N·m (0.20 kgf·m, 18 in·lb)
• Connect the negative (–) cable.
• rosion. coat of grease on the terminals to prevent cor-
Put a light
• For CA model, install the battery as follows.

• battery that
Check the dampers [A] on the battery case [B] and
holder [C].
• The procedure of the installation is the same as the above

mention.
Battery [A]
Positive (+) Cable [B]
Negative (–) Cable [C]
Battery Holder [D]
Battery Holder Nuts [E] and Holder Rods
Battery
Battery Activation (CA Model)
Electrolyte Filling
• Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name
KAF620M: YTX20L-BS
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.
• Place the battery on a level surface.

• or holestoinseeit. that the sealing sheet has no peeling, tears,
Check
• Remove the sealing sheet.

NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
• Remove the electrolyte container from the vinyl bag.

• aside, thesestrip
Detach the of caps [A] from the container and set
will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
Battery
• Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container.
• Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
NOTE
○Be careful not to have the battery fall down.
• Keep the container in place. Don’t remove the container
from the battery, the battery requires all the electrolyte
from the container for proper operation.
NOTICE
Removal of the container before it is completely
empty can shorten the service life of the battery.
Do not remove the container until it is completely
empty.
• 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.
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.)
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.
Charging Condition Inspection

Battery charging condition can be checked by measuring
battery terminal voltage.
• Remove the battery (see Battery Removal).
NOTICE
Be sure to disconnect the negative (−) lead first.
• Measure the battery terminal voltage.

NOTE
○Measure with a digital voltmeter [A] which can be read
to one decimal place voltage.
If the reading is below the specified, refreshing charge is
required.
Battery Terminal Voltage (US Model)
Standard: 12.6 V or more
Battery Terminal Voltage (CA Model)

Battery
Refreshing Charge
• Remove the battery [A] (see Battery Removal).
• Refresh-charge by following method according to the bat-
tery terminal voltage.
WARNING
This battery is sealed type. Never remove seal
sheet [B] even at charging. Never add water.
Charge with current and time as stated below.
(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.
Terminal Voltage: less than 11.5 V

Charging Method: 1.8 A × 20 h
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]
Battery
•○Determine battery condition after refreshing charge.

Determine the condition of the battery 30 minutes after
completion of the charge by measuring the terminal volt-
age according to the table below.
(US Model)
Criteria Judgement
12.6 V or higher Good
12.0 ∼ 12.5 V or lower Charge insufficient → Recharge
12.0 V or lower Unserviceable → Replace
(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
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.
Charging System
• Disconnect the alternator lead connector [A].
• Remove:
Bolts [A]
Breather Cover [B]
Bands [C]
Grommet [D]
• Remove:
Alternator Stator Mounting Screws [A]
Alternator Stator [B]
Alternator Rotor and Stator Installation

• Apply non-permanent locking agent:
Alternator Stator Mounting Screws
• Install:
Stator Coil [A]
Grommet [B]
○Face the slit of the grommet to the engine.
• Install:
Bands [C]
○Tighten the harnesses.
• Install:
New Gasket [A]
Breather Cover [B]
○Face the recesses [C] side of the cover to the engine.
Stator Coil Side [D]
Charging System
• 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]
Charging Voltage Inspection

• Check battery condition.
NOTE
○Always check battery condition before condemning
other parts of the charging system. The battery must
be fully charged in order to conduct accurate charging
system tests.
• Warm up the engine to bring the components up to their

normal operating temperatures.
• Measure regulator/rectifier output voltage at various en-
gine speeds with the headlights turned on and then turned
off.
Charging System
• Connect a voltmeter across the battery terminals.

• the engine speed
The readings should show nearly battery voltage when
is low, and as the engine speed rises,
the readings should also rise. But they must stay within
the specified range.
If the output voltage does not rise as the engine speed
increase then the regulator/rectifier is defective or the al-
ternator output is insufficient for the loads.
If the output voltage is much higher than the specification,
the regulator/rectifier is defective, or the regulator/rectifier
wires are loose or open.
Regulator/Rectifier Output Voltage
Standard: Battery Voltage ∼ 15 V
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.
• To check the alternator output voltage, do the following

procedures.
○Turn the ignition switch OFF.
○Tilt up the cargo bed.
○Open the connector cover.
○Disconnect the alternator lead connector [A].
○Connect a digital meter [B] as shown in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage

Tester Connections Reading at
Range Tester (+) to Tester (–) to 3 000 rpm
AC 250 V One Y lead Another Y lead 45 V or more
If the output voltage shows the value in the table, the al-
ternator operates properly.
If the output voltage shows a much higher than the value
in the table, the regulator/rectifier is damaged. A much
lower reading than that given in the table indicates that
the alternator is defective.
Charging System
•○Check the stator coil resistance as follows.

Stop the engine.
○Connect a digital meter as shown in the table 2.
○Note the readings (total 3 measurement).
Table 2 Stator Coil Resistance at 20°C (68°F)
Tester Connections
Reading
Range Tester (+) to Tester (–) to
×1 Ω One Y lead Another Y lead 0.15 ∼ 0.23 Ω
If there is more resistance than shown in the table, or
no tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
• Using the highest resistance range of a digital meter,
measure the resistance between each of the white leads
and chassis ground.
Any digital meter reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coil has normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Regulator/Rectifier Inspection
• Remove:
Battery (see Battery Removal)
Connector [A]
Regulator/Rectifier Mounting Bolts [B]
Regulator/Rectifier [C]
• Set a digital meter to the × 1 kΩ range and make the

measurements shown in the table.
• Connect a digital meter to the regulator rectifier.
If the tester readings are not as specified, replace the
regulator/rectifier.
Regulator/Rectifier Resistance (Unit: kΩ)
Tester (+) Lead Connection
Terminal W Y1 Y2 Y3 BK/Y
W – ∞ ∞ ∞ ∞
Y1 2.2 ∼ 22 – ∞ ∞
(–)* Y2 2.2 ∼ 22 ∞ – ∞ ∞
Y3 2.2 ∼ 22 ∞ ∞ – ∞
BK/Y 2.2 ∼ 47 2.2 ∼ 22 2.2 ∼ 22 2.2 ∼ 22 –
(–)*: Tester (–) Lead Connection
• Install the regulator/rectifier.

• Tighten:
Torque - Regulator/Rectifier Mounting Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)
Charging System
Charging System Troubleshooting
•Before inspection, remove all accessories that consume
electrical power.
NOTE
○Even when the charging system is working properly, the
battery may discharge if the motorcycle is equipped with
too many accessories.
• Pay attention to riding conditions and the customer’s rid-

ing habits which could affect the charging system such
as:
Frequent use at low engine
speed
→ Battery Discharged
Frequent and unnecessary
brake pedal dragging
• Recharge the battery if it is discharged.

Charging System
Charging System
Charging System Circuit (KAF620M9 ∼ MA/N9/P9 ∼ PA)
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
Charging System
Charging System Circuit (KAF620MB ∼/PB ∼)
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
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.
Spark Plug Removal/Installation

• Remove the
Remove the spark plug cap.
• wrench. spark plugs with a Hex. 19 long type socket
• Tighten:
Torque - Spark Plugs: 17 N·m (1.7 kgf·m, 13 ft·lb)
• Fit the spark plug caps securely.
• installation
Pull up the spark plug caps lightly to make sure of the
of the spark plug caps.
Spark Plug Gap Inspection
• Refer to the Spark Plug Gap Inspection in the Periodic
Spark Plug Cleaning/Inspection
• Refer to the Spark Plug Cleaning/Inspection in the Peri-
Ignition Coil Removal
Front Side
• Remove:
Ignition Coil Leads Connectors [A]
Ignition Coil Bolts [B]
Ignition Coil [C]
Ignition System
Rear Side
•Remove:
Starter Motor (see Starter Motor Removal)
Ignition Coil Lead Connectors [A]
Ignition Coil Bolts [B]
Ignition Coil [C]
Ignition Coil Installation

• Install:
Tube [A] (for rear ignition coil lead)
• 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]
Ignition Coil Inspection

• Measure the ignition coil [C] resistance.
Measure primary winding resistance [A].
Measure secondary winding resistance [B].
Ignition Coil Winding Resistance
Primary Winding: 1.9 ∼ 2.5 Ω at 20°C (68°F)
Secondary Winding: 10.4 ∼ 15.6 kΩ at 20°C (68°F)
If the meter does not read as specified, replace the coil.
If the meter reads as specified, the ignition coil windings
are probably good. However, if the ignition system still
does not perform as it should after all other components
have been checked, test replace the coil with one known
to be good.
• Check the ignition coil lead for visible damage.
If the ignition coil lead is damaged, replace the coil.
Ignition System
Ignition Coil Primary Peak Voltage Inspection
NOTE
• Remove
plug.
the spark plug cap, but do not remove the spark
•○Measure the primary peak voltage as follows.

Connect the peak voltage adapter [A] to a tester [B] (250
V DC range), and install the needle adapter set [C] on the
peak voltage adapter lead.
Special Tools - Needle Adapter Set: 57001-1457
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
○Insert the needle adapter inside the seal until the needle
reaches the terminal in the connector [D].
○Install a new spark plug [E] into the spark plug cap, and
ground it to the engine.
[F] Ignition Coil
[G] ECU
[H] Battery
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
• Turn the ignition switch ON, and run the engine 4 ∼ 5

seconds with the transmission in neutral to measure the
primary peak voltage.
• Repeat the measurements 5 times for one ignition coil.
Ignition Coil Primary Peak Voltage
Standard: 300 V or more
• Repeat the test for the other ignition coil.

If the reading is less than the specified value, check the
following.
Ignition Coils (see Ignition Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
If the ignition coils and crankshaft sensor are normal, see
the Ignition System Troubleshooting chart on page 17-44.
Crankshaft Sensor Removal
• Open the connector cover and disconnect the crankshaft
sensor lead connector [A].
• Remove:
Alternator Cover (see Alternator Rotor and Stator Re-
moval)
Ignition System
• Remove:
Crankshaft Sensor Screws [A]
Crankshaft Sensor [B]
Crankshaft Sensor Inspection

• Disconnect the crankshaft sensor lead connector [A].
• Measure the crankshaft sensor resistance.
Crankshaft Sensor Resistance
Standard: 88 ∼ 132 Ω at 20°C (68°F)
If the resistance is not as specified, replace the crankshaft
sensor.
Crankshaft Sensor Peak Voltage Inspection

NOTE
• Remove the spark plug caps, but do not the spark plugs.
• Crankshaft Sensor Lead Connector [A]
Remove:
• Set a tester [B] to the 10 V DC range.

• crankshaftthesensor
Connect peak voltage adapter [C] to a tester and
leads in the connector.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-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
If the peak voltage is lower than the standard, inspect the
crankshaft sensor.
Ignition System
Resistor Inspection
• Remove:
ment Removal)
Band [A]
• Disconnect the resistor lead connector [B].
• Measure the resistor [A].

Resistor
Standard: About 300 Ω
If the Resistor is not as specified, replace the resistor.
Ignition System
Ignition System Inspection
Ignition System
Ignition System Circuit
1. ECU Relay
2. ECU
7. Ignition Switch
8. Neutral Switch
10. Battery
11. Fuse Box 1
12. Main Fuse 30 A
16. Crankshaft Sensor
17. Resistor (300 Ω, 1 W)
18. KAF620MC ∼/PC ∼
Starter Motor Removal
• Remove:
Starter Motor Leads (from Starter Motor) [A]
Starter Motor Mounting Bolts [B]
Starter Motor [C]
Starter Motor Installation

• Clean the mating surface [A] of the starter motor and the
crankcase where the starter motor is grounded [B].
• Install the starter motor and tighten the mounting bolts.
Torque - Starter Motor Mounting Bolts: 21.6 N·m (2.2 kgf·m,
16 ft·lb)
Starter Motor Disassembly

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

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

the brush plate [A].
If there is not close to 0 Ω, the brush plate has an open.
Replace the brush plate.
• Measure the resistance between the brush plate and the
(+) brush holder [B].
If there is any reading, the brush plate has a short. Re-
place the brush plate.
Commutator Cleaning/Inspection
• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
• Measure the diameter [A] of the commutator [B].

Replace the starter motor with a new one if the commu-
tator diameter is less than the service limit.
Commutator Diameter
Standard: 30 mm (1.18 in.)
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.
Starter Switch Inspection

•○Connect a 12 V battery to the starter switch [A] as shown.
Connect the battery negative (–) cable [B] first and then
the positive cable to the terminal in the connector [C].
If the switch does not work as specified, the switch is de-
fective. Replace the starter switch.
Testing Switch
Criteria: When battery is connected → Pinion gear
must move outward quickly.
When battery is disconnected → Pinion gear
must return quickly.
Starter Relay Removal
• Remove:
Control Panel Cover (see Control Panel Cover Removal
in the Frame chapter)
Battery Negative Cable
• Disconnect:
Starter Motor Cable [A]
Battery Positive Cable [B] and Cover
Connector [C]
• Remove:
Starter Relay [D]
Starter Relay Inspection
• Remove the starter relay (see Starter Relay Removal).
• Connect the hand tester [A] and a 12 V battery [B] to the
starter relay as shown in the figure.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Hand Tester Range: × 1Ω range
Criteria: When battery is connected ⇒ 0 Ω
When battery is disconnected ⇒ ∞Ω
Starter Relay Installation

• Connect
figure.
the cables to the starter relay [A] as shown in the
Starter Motor Cable [B]

Battery Positive Cable [C] and Cover
Connector [D]
Starter Circuit Relay Inspection

• Remove:
Starter Circuit Relay [A]
Starter Circuit Relay Connector [B]
• Connect a digital meter [A] and 12 V battery [B] to the

starter circuit relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Criteria: When battery is connected ⇒ 0 Ω
When battery is disconnected ⇒ ∞ Ω
Electric Starter Circuit
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)
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 (–)
Radiator Fan Breaker Inspection

• Lift up the seat.
• Remove:
Radiator Fan Breaker [A]
• Inspect the breaker for operation.

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

Radiator Fan Breaker [C]
Switch [D]
If the circuit in the breaker will not open within 60 seconds,
replace the breaker.
• Install:
Radiator Fan Breaker [A]
Holder [B]
Front [C]
Bracket [D]
Radiator Fan System
Radiator Fan Circuit
1. Radiator Fan
2. Radiator Fan Breaker
3. Radiator Fan Relay
4. ECU
6. Battery
Lighting System
Headlight Beam Adjustment
• Turn the adjusting screw [A] on each headlight in or out
to adjust the headlight vertically.
Headlight Bulb Replacement

• Remove the front cover (see Front Cover Removal in the
Frame chapter).
• Turn the headlight bulb [A] counterclockwise [B] and pull
out the bulb from the headlight.
• Replace the headlight bulb.

• headlight.
Fit the projections [A] of the bulb in the hollows [B] of the
• Turn the headlight bulb [A] clockwise [B].

• Install the front cover (see Front Cover Installation in the
Frame chapter).
Headlight Removal
• Remove:
chapter)
Bolts [A] (KAF620M9 ∼ MB/N9/P9 ∼ PB)
Screws [A] (KAF620MC ∼/PC ∼)
Screws [B]
Lighting System
Headlight Installation
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).
Tail/Brake Light Replacement

• Remove:
Screws [A]
Tail/Brake Light Lens [B]
• 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.
Light Switch Bulb Replacement

Compartment Removal in the Frame chapter).
• Turn
bulb.
the socket [A] counterclockwise, and pull it with the
Lighting System
• Pull the bulb [A] out of the socket.

NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb.
Do not use bulb rated for greater wattage than the
specified value.
• Insert the new bulb in the socket.

• Align the projections [A] of the socket with the recesses
[B] in the switch body, and turn the socket clockwise.
Lighting System Circuit
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
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]
Lighting System
Indicator Light Circuit
1. Parking Brake Light Switch

2. Frame Ground Terminal
3. ECU Relay
4. ECU
7. Water Temperature Warning Indicator Light
8. Parking Brake Indicator Light
9. Ignition Switch
11. Battery
12. Fuse Box 1
13. Main Fuse 30 A
Meter (KAF620MD ∼/PD ∼)
Fuel Gauge/Hour Meter Removal
Compartment Removal in the Frame chapter).
• Clear the clips [A] and remove the stopper [B].
• Remove the fuel gauge/hour meter [C].
Fuel Gauge/Hour Meter Installation

•○Installation is the reverse of removal.
Run the harness, cables and leads correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
Fuel Gauge (LED) Inspection
• Remove the fuel gauge/hour meter (see Fuel Gauge/Hour
Meter Removal).
[1] Battery (–)
[2] Battery (+)
[4] Fuel Level Gauge
• Using the auxiliary leads, connect the 12 V battery to the

fuel gauge/hour meter connector as follows.
Battery Positive (+) Terminal to Terminal [2]
Battery Negative (–) Terminal to Terminal [1]
• Connect the variable rheostat [A] to the terminal [4].
• Check that the number of segments [A] matches the re-

sistance value of the variable rheostat.
○The number of fuel gauge segments increases or de-
creases one by one every 10 seconds.
Variable Rheostat
Display Segments
Resistance (Ω)
10 10
120 1 (blink)
If the fuel gauge display function does not work, replace
the fuel gauge/hour meter.
Switches
Brake Light Switch Adjustment
• Refer to the Brake Light Switch Adjustment in the Periodic
Water Temperature Sensor Inspection
• Remove:
Water Temperature Sensor (see Water Temperature
Sensor Removal/Installation in the Fuel System (DFI)
chapter)
• Suspend the sensor [A] in a container of coolant so that
the threaded portion is submerged.
• Suspend an accurate thermometer [B] with temperature
sensing portions [C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the con-
tainer side or bottom.
• Place the container over a source of heat and gradu-

ally raise the temperature of the coolant while stirring the
coolant gently.
• Using the digital tester, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the table.
If the tester does not show the specified values, replace
the sensor.
Water Temperature Sensor Resistance
Temperature Resistance
20°C (68°F) 2.32 ∼ 2.59 kΩ
80°C (176°F) 310 ∼ 326 Ω
110°C (230°F) 139.9 ∼ 143.5 Ω
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
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.

○Refer to the tables in the Wiring Diagram for the switches
other than the above.
Fuses
Fuse Removal
• Lift up the seat.
• Unlock the hook to lift up the lids [A].
Fuse Box 1 [B]
Fuse Box 2 [C]
• 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
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)
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
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
Fuse blown
Spark plug cap shorted or not in good con-
Compression Low:
tact
Spark plug loose
APPENDIX 18-3
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
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
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. Coolant Reserve Tank

2. Radiator Overflow Hose
3. Run the radiator overflow hose under the bracket of the frame.
4. Viewed from upper
5. Front
6. Radiator
7. Viewed from front
APPENDIX 18-7
1. Differential Shift Cable 10. Clamp of Frame

2. Throttle Cable 11. Front
3. Transmission Shift Cable 12. Right Leaf Spring
4. Hi/Low Shift Cable (KAF620M/N) 13. Left Leaf Spring
5. 2WD/4WD Shift Cable (KAF620M/N) 14. Viewed from upper
6. Bands 15. Main Harness
7. Right Parking Brake Cable 16. Resistor
8. Left Parking Brake Cable 17. KAF620MC ∼/PC ∼
9. Clamp 18. Viewed from rear
18-8 APPENDIX
KAF620M9 ∼ MC/N9/P9 ∼ PC
APPENDIX 18-9
1. Right Headlight Lead
2. Clamps
3. Bands
4. Power Outlet Connector
5. Ignition Switch
6. Hour Meter
7. EPS Warning Indicator Light (LED) (KAF620M/N)
12. Headlight Switch
13. EPS ECU (KAF620M/N)
14. Front Cargo Hood Cable
15. Clamp
16. EPS Torque Sensor Connector (KAF620M/N)
17. Left Brake Hose
18. Front Final Gear Case Breather Hose (KAF620M/N)
19. To Horn
20. Radiator Fan Motor Lead
21. Fix the ground lead terminal to the steering gear assembly.
23. Left Headlight Lead
24. EPS Motor Connector (KAF620M/N)
25. Detail A
26. Detail B
27. Accessory Terminals
28. Viewed from rear
29. Viewed from front
30. Horn Switch Lead
31. Run the horn switch lead to the straightly down (Do not twist it around the steering shaft.).
32. Detail C
33. 25 mm (0.98 in.)
34. Viewed from D
35. Steering Gear Assembly
36. Clamps
37. Horn Lead
18-10 APPENDIX
KAF620MD ∼/PD ∼
APPENDIX 18-11
1. Right Headlight Lead
2. Clamps
3. Bands
4. Power Outlet Connector
5. Ignition Switch
6. Fuel Gauge/Hour Meter
7. EPS Warning Indicator Light (LED) (KAF620M)
12. Horn Switch
13. Headlight Switch
14. EPS ECU (KAF620M)
15. Front Cargo Hood Cable
16. Clamp
17. EPS Torque Sensor Connector (KAF620M)
18. Left Brake Hose
19. Front Final Gear Case Breather Hose (KAF620M)
20. To Horn
21. Radiator Fan Motor Lead
22. Fix the ground lead terminal to the steering gear assembly.
24. Left Headlight Lead
25. EPS Motor Connector (KAF620M)
26. Detail A
27. Detail B
28. Accessory Terminals
29. Viewed from rear
30. Viewed from C
31. Steering Gear Assembly
32. Clamps
33. Horn Lead
18-12 APPENDIX
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
1. Band 13. Frame Ground Terminal

2. Band 14. Band
3. EPS 40 A Fuse (KAF620M/N) 15. Clamp (KAF620M/N)
4. EPS 7.5 A Fuse (KAF620M/N) 16. EPS Self-diagnosis System Connector
5. Fuse Box 1 (KAF620M/N)
6. Fuse Box 2 17. Band
7. Radiator Fan Breaker 18. ECU
8. Clamps 19. Band
9. To Fuel Pump 20. Regulator/Rectifier
10. KDS Connector 21. White Mark
11. Band 22. White Tapes
12. Band
18-14 APPENDIX
KAF620ME/PE
1. US Model
2. CA Model
5. Starter Relay Cable
6. Red Cap
7. Diode
8. Band
9. Band
10. Starter Relay
11. Trim
APPENDIX 18-15
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
1. Battery Positive Cap

2. Main Harness
5. Front
6. Band
7. Do not bring positive cable into contact with the bolt head on the negative cable.
8. Viewed from A
APPENDIX 18-17
This page intentionally left blank.
18-18 APPENDIX
APPENDIX 18-19
1. Front
2. Bands
3. Clamps
4. White Tape
5. Subthrottle Sensor Lead Connector
6. Main Throttle Sensor Lead Connector
7. Inlet Air Temperature Sensor Lead Connector
8. Subthrottle Valve Actuator Lead Connector
9. Fuel Injector #2 Lead Connector
10. Inlet Air Pressure Sensor Lead Connector
11. Fuel Injector #1 Lead Connector
12. Starter Motor, Oil Pressure Switch and Ignition Coil Lead Connector
13. Crankshaft Sensor Lead Connector
14. Alternator Lead Connector
15. Connect the leads as shown in the figure.
16. Breather Hose (KAF620M9 ∼ MD/N9/D9 ∼ PD)
17. Clamp (KAF620M9 ∼ MD/N9/D9 ∼ PD)
18. KAF620ME/PE
18-20 APPENDIX
KAF620M/N
1. Differential Shift Cable

2. Clamp
3. About 100 mm (3.9 in.)
4. Clamp
5. 2WD/4WD Shift Cable
APPENDIX 18-21
KAF620MB ∼/PB ∼ (other than CAL Model)
1. Fuel Tank
2. Check Valve
3. Band
4. Clamps
18-22 APPENDIX
KAF620M9 ∼ MA/N9/P9 ∼ PA (other than CAL Model)
1. Front
2. Clamp
3. Clamp
4. Fuel Hose
5. Fuel Pump
APPENDIX 18-23
CAL Model and KAF620MB ∼ MC/PB ∼ PC
1. Front
2. Check Valve
4. Canister
5. Band
6. Breather Hose
8. Clamps
9. Fuel Filter
11. Fuel Hose
12. Fuel Pump
13. Viewed from A
18-24 APPENDIX
KAF620MD/PD
1. Front
2. Check Valve
4. Canister
5. Band
6. Breather Hose
8. Clamps
9. Fuel Filter
11. Fuel Hose
12. Fuel Pump
13. Viewed from A
APPENDIX 18-25
KAF620M9/N9/P9 (Early Model)
1. Front Brake Master Cylinder

2. Keep the brake hose away from the EPS unit. (KAF620M/N)
Keep the brake hose away from the steering intermediate shaft. (KAF620P)
3. Left Brake Hose
4. Right Brake Hose
5. Band
6. Main Harness
7. Clamps
8. Breather Tube (L = 1 480 mm (58.3 in.))
9. Bands
10. Brake Pipe
18-26 APPENDIX
KAF620M9/N9/P9 (Late Model) and Later Model
1. Breather Tube (L = 1 100 mm (43.3 in.))

2. Brake Hose
3. Push the tube into the hole of case storage.
4. Clamp
5. Bands
6. Front
APPENDIX 18-27
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.
Part No.99924-1406-07 Printed in Japan

Mule 4010-4000 4x4 en Ingles

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Mule 4010-4000 4x4 en Ingles

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MULE 4010 4×4

This quick reference guide will assist

COUNTRY AND AREA CODES

MULE 4010 4×4: KAF620M/N

that are necessary when servicing Kawasaki • Indicates

Cleaning Vehicle before Disassembly

Storage of Removed Parts

Liquid Gasket, Non-permanent Locking Agent

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Apply specified grease to the lip of seal before installing

Circlips, Cotter Pins

Direction of Engine Rotation

KAF620M9 Right Side View

Frame Number Engine Number

KAF620N9 Right Side View

KAF620P9 Right Side View

Items KAF620M9 ∼ ME/N9

Items KAF620M9 ∼ ME/N9

Items KAF620M9 ∼ ME/N9

Units of Volume: Units of Pressure:

Units of Force: Units of Power:

Fuel hoses - replace 5 years 2-15

Coolant - change 2 years 2-19

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

Seat belt - inspect • 2-43

Letters used in the “Remarks” column mean:

Basic Torque for General Fasteners of Frame Parts

Item Standard Service Limit

Item Standard Service Limit

Valve Adjusting Screw Holder:

Throttle Pedal Free Play Adjustment

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

Idle Speed Inspection

• Loosen the locknut [A].

If the idle speed is out of the specified range, check the

•○Install the cover [A] and lock the clamps.

Air Cleaner Housing Dust or Water Draining

Fuel Hoses or Pipe and Connections Inspection

• Tilt up the seat and cargo bed.

When removing with standard tip screwdriver

• Clean the pipe [A].

• Remove the vinyl bag on the pipe.

• Repeat the previous step to remove the other side of the

Evaporative Emission Control System Inspection

• Check the hoses of the evaporative emission control sys-

• Place a container under the drain plugs.

Coolant Drain Plugs [A] at Water Pipes

• Place a container under the drain plug.

• Place a container under the drain plug.

Coolant Drain Plug [A] at Rear Cylinder

Water and Coolant Mixture Ratio (Recommended)

• Install the reserve tank cap.

Water Hose and Connection Inspection

• Turn the alternator rotor clockwise so that the mark "1"

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

Valve Clearance Adjustment

• Holding the adjusting screw with the holder [C], tighten

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

• Stop the engine.

• Remove the air cleaner element, and separate the foam

Converter Drive Belt Inspection

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

Drive Belt Deflection Inspection