He TERYX 750 Fl 4x4 TERYX 750 Fl 4x4 LE = Kawasaki tervx 750 F1 4x4 sport Recreation Utility Vehicle Service ManualThis quick reference guide will assist you in locating a desired topic or pro- cedure, *Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. +Refer to the sectional table of contents for the exact pages to locate the spe- Gific topic required. Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI Cooling System Engine Top End Converter System Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix O} |} | 00] |a} | o>} Jon} | | | oo] |r] |=TERYX 750 FI 4x4 TERYX 750 FI 4x4 LE : Kawasaki TERYX 750 Fl 4x4 SPORT Recreation Utility Vehicle Service Manual Alll 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. © 2009 Kawasaki Heavy Industries, Ltd Gth Edition (2): Apr. 16, 2012LIST OF ABBREVIATIONS A ampere(s) Ib 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 pc direct current pm revolution(s) per minute F farad(s) Toc top dead center 7 degree(s) Fahrenheit TIR total indicator reading ft foot, feet v volt(s) 9 gram(s) w watts) h hour(s) a ohm(s) L liter(s) COUNTRY AND AREA CODES cA Canada us United States TERYX 750 Fl 4x4: TERYX 750 Fl 4x4 LE: TERYX 750 Fl 4x4 SPORT: KRF7SON/T Models KRF7SOPIRIV Models KRF750S Model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. 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. Then, itis led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber fromthe crankcase, and then returned back to the bottom of crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a catalytic converter in the muffler (US and CA models), a fuel injection and ignition system having optimum ignition timing characteristics. The fuel injection system has been calibrated to provide lean airifuel mixture characteristics and opti- mum fuel economy with a suitable air cleaner and exhaust system. ‘A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere. 3. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank. 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 moter vehicle engine in compliance with regulations under this title follow- ing its sale and delivery to the ultimate purchaser...” NOTE oThe 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. ¢.Addition of components or accessories that resultin the vehicle exceeding the stan- dards.d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission contro! 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 intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any way \Which results in an increase in noise level. TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed of rendered inoperative by any person. Do not tamper with the original emission related parts: ¢ Throttle body and internal parts Spark plugs ‘Alternator or electronic battery ignition system Fuel fiter/Fuel injector/Fuel pump cleaner element * ECU (Electronic Control Unit)Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop, However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: ‘* Follow the Periodic Maintenance Chart in the Service Manual ‘*Be alert for problems and non-scheduled maintenance. ‘© Use proper tools and genuine Kawasaki Vehi- cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man- ual. Genuine parts provided as spare parts are listed in the Parts Catalog. ‘© Follow the procedures in this manual care- fully. Don't take shortcuts ‘* Remember to keep complete records of main- tenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system ‘and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta- ble of Contents, For example, if you want engine oil informa- tion, use the Quick Reference Guide to locate the Engine lubrication System chapter. Then, use the Table of Contents on the first page of the chapter to find the Engine Oil section. Whenever you see symbols, heed their in- structions! Always follow safe operating and maintenance practices. Pa DANGER indicates a hazardous situa- tion which, if not avoided, will result in death or serious injury. AWARNING WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. This manual contains four more symbols which will help you distinguish different types of information NOTE This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. Indicates a procedural step or work to be done. Olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. x Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing 12 Mode! Identification 17 General Specifications. 4-12 Unit Conversion Table 1-164-2 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 wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (-) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (¥) terminal of the battery then the negative (-) wire 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-flush point solvent when cleaning parts. High -flush 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.GENERAL INFORMATION 1-3 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.1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts nuts, or screws, first loosen all of them by about a quar- ter turn and then remove them. If the specified tightening ‘sequence is not indicated, tighten the fasteners alternating diagonally. eee 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. Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench. Force Use common sense during disassembly and assembly, + excessive force can cause expensive or hard to repair dam- KES age. When necessary, remove screws that have a non PEE -permanent locking agent applied using an impact driver. ¢ Sske\ 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 per- formance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when reassembling Liquid Gasket, 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 locking agent. Do not apply them excessively. Exces- sive application can clog oil passages and cause serious damage.GENERAL INFORMATION 1-5 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 newoil 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 circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when in- stalling to prevent deformation ae1-6 GENERAL INFORMATION 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GENERAL INFORMATION 1-7 Mode! Identification KRF75ONA, TA Left Side View KRF75ONA, TA Right Side View [A] Frame Number [A] Engine Number IB] Right Front Axle [8] Engine Oil Drain Plug1-8 GENERAL INFORMATION Model Identification KRF750NC Left Side View KRF750NC Right Side ViewGENERAL INFORMATION 1-9 Mode! Identification KRF75OPA Left Side View KRF750PA Right Side View1-10 GENERAL INFORMATION Model Identification KRF750RA, VB Left Side View ‘The KRF75ORA, VB are identical to the KRF7SOPA in every aspect: controls, features, and specifications except for the camouflage surface treatment. The gun case is an optional part.GENERAL INFORMATION 1-11 Mode! Identification KRF750SA Left Side View1-12 GENERAL INFORMATION General Specifications Items KRF750NA/PA/RA/SA/TA/VB ~ ND/PD/RDISDIVC. Dimensions Overall Length }2 955 mm (116.3 in.) Overall Width 1 485 mm (68.46 in.) Overall Height (KRF750N/ST) 1.925 mm (75.79 in.) (KRF750P/R/V) 2.020 mm (79.53 in.) Wheelbase 1.930 mm (75.98 in.) Tread: Front 1225 mm (48.23 in.) Rear 1.200 mm (47.24 in.) Ground Clearance 295 mm (11.6 in.) Seat Height 780 mm (30.7 in.) Curb Mass: (KRF75ONA ~ NB) }633 kg (1396 Ib), (CA) 630 kg (1 389 Ib) (KRF750NC) }636 kg (1.402 Ib), (CA) 633 kg (1 396 Ib) (KRF750ND) }634 kg (1.398 Ib), (CA) 631 kg (1.391 Ib) (KRF7SOPA/RA ~ PB/RB/VB) | 648 kg (1429 Ib), (CA) 645 kg (1 422 Ib) (KRF750PC/RCIVC) }651 kg (1 435 Ib), (CA) 648 kg (1 429 Ib) (KRF7S50PD/RD) }649 kg (1431 Ib), (CA) 646 kg (1 424 Ib) (KRF750SA ~ SB) (KRF750SACA ~ SBCIA) (KRF750SC) (KRF750SD) (KRF750T) Front: (KRF750NA ~ NB) (KRF75ONC) (KRF75OND) (KRF750PAIRA ~ PB/RB/VB) (KRF750PC/RCIVC) (KRF750PD/RD) (KRF750SA ~ SB) (KRF750SACA ~ SBCA) (KRF750SC) (KRF750SD) (KRF750T) Rear: (KRF750NA ~ NB) (KRF750NC) (KRF750ND) (KRF7S0PA/RA ~ PB/RB/VB) (KRF750PC/RCIVC) (KRF750PD/RD) (KRF750SA ~ SB) }630 kg (1.389 Ib), (CA) 627 kg (1 383 Ib) }631 kg (1.391 Ib), (CA) 628 kg (1 385 Ib) }633 kg (1.396 Ib), (CA) 630 kg (1 389 Ib) }631 kg (1 391 Ib), (CA) 628 kg (1 385 Ib) 1634 kg (1 398 Ib) 280 kg (617 Ib), (CA) 279 kg (615 Ib) 281 kg (620 Ib), (CA) 280 kg (617 Ib) 278 kg (613 Ib), (CA) 277 kg (611 Ib) }291 kg (642 Ib), (CA) 289 kg (637 Ib) }292 kg (644 Ib), (CA) 291 kg (642 Ib) }289 kg (637 Ib), (CA) 288 kg (635 Ib) }279 kg (615 Ib), (CA) 278 kg (613 Ib) 280 kg (617 Ib), (CA) 279 kg (615 Ib) 280 kg (617 Ib), (CA) 279 kg (615 Ib) 277 kg (611 Ib), (CA) 276 kg (609 Ib) 1281 kg (620 Ib) 353 kg (78 Ib), (CA) 351 kg (774 Ib) 355 kg (783 Ib), (CA) 353 kg (78 Ib) 356 kg (785 Ib), (CA) 354 kg (780 Ib) 357 kg (787 Ib), (CA) 356 kg (785 Ib) 359 kg (792 Ib), (CA) 357 kg (787 Ib) 360 kg (794 Ib), (CA) 358 kg (789 Ib) 351 kg (74 Ib), (CA) 349 kg (770 Ib)GENERAL INFORMATION 1-13 General Specifications Items. KRF750NA/PA/RA/SA/TAIVB ~ ND/PDIRD/SDIVC (KRF750SAQA - SBA) 351 kg (774 Ib), (CA) 349 kg (770 Ib) (KRF750SC) 353 kg (78 Ib), (CA) 351 kg (774 Ib) (KRF750SD) 354 kg (780 Ib), (CA) 352 kg (776 Ib) (KRF750T) 353 kg (78 Ib), (CA) 351 kg (774 Ib) Fuel Tank Capacity Cargo Bed (L « Wx H) Seating Capacity 28 L (7.4 US gal) 830 x 1 120 x 280 mm (32.68 x 44.09 « 11.10 in.) 2 Performance Minimum Turning Radius: Differential Mode (2WD) Locked-Axle Mode (4VVD) 42 m (13.8 ft) 5.0 m (16.4 ft) Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing ‘Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Intake: Open Close Duration Exhaust: Open Close Duration Lubrication System. Engine Oil: Type Viscosity Capacity 4-stroke, SOHC, V2-cylinders. Liquid-cooled 185.0 x 66.0 mm (3.35 x 2.60 in.) 749 cm? (45.7 cu in.) 88:1 57 Nem (6.8 kgf'm, 42 fb) @5 000 r/min (rpm) Fuel Injection (Mikuni 434 x 2) Electric Starter Battery and Coil (transistorized) Electronically advanced (digital) 10° BTDC @1 110 timi (tpm) NGK CR7E or DENSO U22ESR-N Front to rear, 1-2 12 20° BTDC 44° ABDC. 244° 44° BBDC 20° ATDC. 244° Forced lubrication (wet sump) API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA SAE 10W-40 2.6L (2.7 US qt)1-14 GENERAL INFORMATION General Specifications Reduction Ratio Transmission Gear Ratio: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Items KRF750NA/PA/RA/SA/TA/VB ~ ND/PD/RDISD/VC Drive Train Primary Reduction System: Type Belt drive torque converter 3,200 ~ 0.721 3.549 (30/26 x 29/18 x 21/11) 5.536 (36/20 x 29/18 x 21/11) 4.614 (16/12 * 18/16 x 29/18 x 21/11) Shaft 4WD/2WD_ 4.375 (35/8) Steering Type Forward: High 11.195 Low 17.464 Reverse 14.553 Front Final Gear Case Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 0.7 L (0.74 US at Rear Final Gear Case Oil Type MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Capacity 1.0 L (1.06 US gt) Frame Type Steel tube, Ladder Caster (Rake Angle) 22° Camber: (Front) -0.7" (Rear) -0.4" King Pin Angle 11.4" T 11 mm (0.43 in.) Tire’ Front: Type Tubeless Size 26 x 8.00- 12 Rear: Type Tubeless Size 126 * 10.00 - 12 Rim Size Front 12 « 6.0AT Rear 12 x 8.0AT Rack and pinionGENERAL INFORMATION 1-15 General Specifications Parking Brake Type Items. KRF750NA/PA/RA/SA/TAIVB ~ ND/PDIRD/SDIVC Suspension: Front: Type Double Wishbone Wheel Travel 190 mm (7.48 in.) Rear: Type Double Wishbone Wheel Travel 190 mm (7.48 in.) Brake Type: Front Disc x 2 Rear Enclosed wet multi-plate Enclosed wet multi-plate Electrical Equipment Battery (US) 12 V 14 Ah, (CA) 12 V 12 Ah Headlight: Type ‘Semi-sealed beam Bulb 12.V 35/35 Wx 2 Brake/Tail Light 12.V 2718 Wx 2 Alternator: Type Three - phase AC Max Output 28 A, 14 V @8 000 rpm Load Capacity Maximum Vehicle Load (Including Occupants and Cargo) Maximum Cargo Bed Load 422 kg (931 Ib) 227 kg (500 Ib) 1: This blank changes depending on the model. ‘Specifications are subject to change without notice, and may not apply to every country.1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: km x 06214 = mile Prefix | Symbol Power m x 3.281 f mega M = 1000 000 mm x 0.03937 in kilo k * 1.000 centi c * 0.01 mil m * 0.001 Units of Torque: micro uw x 0.000001 Nem x 0.1020 kgfm Nm x 0.7376 ft'lb Nm x 8.851 indb kgfm 9.807, Nm Units of Mass: kgfm x 7.233, ftlb: kg x 2.205 = Ib kgf'm x 86.80 = in-b a * (003527 oz Units of Pressure: Units of Volume: kPa x 0.01020 kgfiem?® L * 0.2642 - gal (US) kPa * 0.1450 psi L * 0.2200 gal (IMP) kPa x 0.7501 emHg i x 1.057, at (US) kgficm? 98.07 kPa L x 0.8799 qt (IMP) kgficm? x = 14.22 psi L x 2113 = pint (US) cmHg x = 1.333. = kPa L x 1.816 pint (IMP) me * 0.03381 oz (US) mL x 0.02816 oz (IMP) Units of Speed: me * 0.06102 = eu in km/h * 06214 = mph Units of Force: Units of Power: Nx 0.1020 kg KW x 1.360 Ps Nx 02248 Ib KW 1344 HP kg *~~-9.807 N PS 0.7355 KW kg x 2205 = Ib Ps. x 09863 = HP Units of Temperature: ote. CO SCF +49) _ garg F °F 43268108 ee PP | 8 0p) Apo ego sg se 200 270 20 | 20 20) 90s Rectan fecteeataleteeater eat t—1-+ ieee T—— wi of tw 10 n040 160 Pree ees aA oh Mae CT eI °PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Agent Specifications Special Tools . Poriodic Maintonance Procedures. Fuel System, Throttle Pedal Free Play Inspection Throttle Pedal Free Play Adjustment... Idle Speed Inspection Idle Speed Adjustment - Air Cleaner Element Cleaning and Inspection Ali Cleaner Draining. i Fuel Hose and Connections Inspection Fuel Hose Replacement Cooling System, Radiator Cleaning... Water Hoses and Connections Inspection . Coolant Change Engine Top End Valve Clearance Inspection .. Valve Clearance Adjustment... ‘Spark Arrester Cleaning. Converter System.. : Converter Drive Belt Wear Inspection... Drive Belt Deflection Inspection Converter Drive Belt Deflection Adjustment, Actuator Lever (Engine Brake Control Lever) Assembly Inspection Engine Lubrication System..... : a i Engine Oil Change.. Oil Filter Replacement Wheels/Tires Tire Inspection Wheels Nuts Tightness Inspection Final Drive... ai Differential Shift Lever Play Inspection... Differential Shift Lever Play Adjustment. Front Final Gear Case Oil Change Rear Final Gear Case Oil Change Brakes, Brake Fluid Level inspection. Brake Fluid Change Brake Pedal Play Inspection Brake Master Cylinder Cup and Dust Seal Replacement. Rear Brake Master Cylinder Cup, O-ring and Boot Replace Brake Hose and Pipe Inspection Brake Hose Replacement. Parking Brake Pedal Inspection Front Brake Pad Wear Inspection Front Brake Caliper Piston Seal and Dust Seal Replacement Rear Brake Plates Replacement. 2:35 2:36 2-36 2-37 2-38 2:39 2-42 2-42 2-44 2-44 2-45 2-462-2 PERIODIC MAINTENANCE Steering Steering Inspection Steering Joint Dust Boot Inspection Frame Seat Belt Inspection Electrical System. Spark Plug Cleaning/inspection.. Spark Plug Gap Inspection... Brake Light Switch Inspection... Brake Light Timing Adjustment.. Joint Boots Inspection. Front Axle/Steering Knuckle Joint Boots Inspection . Front Propeller Shaft Joint Boots Inspection. Tie-tod End Boots inspection... Rear Propeller Shaft Joint Boots Inspection. Rear Axle/Stabilizer Joint Boots Inspection General Lubrication... : : Lubrication .. Cables. Inspection... Bolts and Nuts Tightening Tightness Inspection 2-46 2-46 2-47 2-47 2-47 2-48 2-48 2-49 2-49 2-49 2-49 2-49 2-50 250 2-50 2-50 2-50 2-50 2-51 251 2-52 2-52PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The i itial maintenance is vitally important and must not be neglected. FREQUENCY] First Service Regular Service After | After | Every | Evory | Every 20h, | 50h, | 50h, |100h, 20h, 200 |1 G00 1 G00 |2.000 4 000 | Ever¥ i. km | km | km |km (1) km (2 oe (120 | 600 | oo | 200 S00 rmile) | rile) | mile) | mile) | mile) OPERATION of use |of use | of use of use of use ENGINE Throttle pedal play-inspect . © | 26 Fuel hoses and connections-inspect ° 218 Fuel hose-replace 5 years 2419 Idle speed-inspect . . 27 ‘Spark plug-elean and gap inspect : . 2-48 Air cleaner-inspect * : . 27 Valve clearance-inspect Ee lat a oon kere bon re ok ‘Spark arrester-clean : 2:26 Engine oll-change * : 6 months 232 Oil fiterreplace * : 2 | 233 Front and rear final gear case oil-change | elas Radiator-clean * . . 224 Water hoses and connections-check * © [224 Coolant-change * 2 years 224 Converter drive belt wear-inspect * . 227 Converter drive belt deflection-inspect" | . 2:29 Differential shift lever play-inspect . . 234 Engine brake control lever-inspect * . 231 CHASSIS. Rear brake plates-replace * ‘every 10 000 km (6 000 mile) 246 Front brake pad woar-inspect * . 244 Brake light switch - inspect : 2-48 Brake fluid - change 2 years 2:36 Brake master cylinder cup and dust sea a aa Rea: brake master onde cup, On, ee ey Front brake caliper piston seal and dit 2 years cae Brake hose - replace 4 years 242 Brake fluid level - inspect : . 236 Brake pedal play - inspect * . . 2382-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY | First Service Regular Service After | After | Every | Every | Every 20h, | 50h, | 50h, [100 h, 200 h. or | or | or | or | or 200 | 1 000 | 1 0002 000, 4 000 | Every Pee km | km | km | km (1 | km (2) Yen, (120 | (600 | (600 | 200 | 500 mile) | mile) | mile) | mite) | mile) OPERATION of use | of use | of use |of use of use Brake hose and pipe - inspect . ° 2-41 Parking brake pedal - inspect . . 244 Tire wear-inspect * . . 233 Wheel nuts tightness - inspect . . 234 Joint boots = inspect : . 2-49 Steering-inspect : : 2-46 Steering joint dust boots - inspect . . 247 General lubrication - perform * . 2.50 Bolts, nuts, and fasteners tightness - ; . oo inspect Seat belt - inspect . 247 Cables - inspect . 251 *: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy loads ot pulling a trailer. ¢:Clean, adjust, lubricate, torque, or replace parts as necessary.PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue) LO: Apply a non-permanent locking agent (Three Bond TB2440B, Orange). Lh: Left-hand Threads MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in ‘a weight ratio: 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120) Torque Fastener wm] kot [eae Remarks Fuel System Element Holder Screw 45 | 0.46 | 40 intb Element Cover Screw 45 | 046 | 40 intb Air Cleaner Mounting Bolts, 38 | 0.90 | 78 inib L ISC Valve Mounting Bolts 38 | 090 | 78 inib Delivery Pipe Mounting Screws 5.0 | 051 | 44 inp Intake Air Pressure Sensor Mounting Screw 5.0 | 051 | 44 inp Throttle Cable Locknuts 44 | 048 | 39 intb Throttle Pedal Position Bolt Locknut 108 | 14 | 96 intb Fuel Pump Mounting Bolts 40 | 0.41 | 35 intb Fuel Tank Band Bolts " 14 | 97 inp ECU Mounting Bolts 69 | 070 | 61 intb Water Temperature Sensor 12 12 | 108 int Vehicle-down Sensor Bolts (KRE7SONDIPDIRDISD) |_59 | 0.60 | 82 intb L Cooling System Radiator Screen Mounting Bolts 8s | 090 | 78 intb Radiator Cover Bracket Mounting Bolts 8s | 090 | 78 intb Radiator Mounting Botts 8s | 090 | 78 intb Radiator Fan Assembly Bolts, 33 | 08s | 73 inp Thermostat Housing Cover Bolts 38 | 090 | 78 inib Water Temperature Sensor 12 12 | 106 intb Water Pipe Mounting Bolts, L = 20 mm (0.79 in.) 8s | 090 | 78 intb Water Pipe Mounting Bolt, L = 12 mm (0.47 in.) 88 | 090 | 78 intb Water Pump Impeller 78 | 0.80 | 69 inib Water Pump Cover Bolts 38 | 090 | 78 inib Coolant Drain Plug (Water Pump) 70 | 071 | 62 inp Coolant Drain Plugs (Cylinder) 70 | 071 | 62 inp Coolant Air Bleed Bolt (Water Pump) 70 | 071 | 62 intb Coolant Air Bloed Bolt (Thermostat) 78 | 080 | 69 intb Radiator Cover Mounting Bolts (KRF7SONDIPDIRDISD) eee | arcane ec2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener a Engine Top End Valve Adjusting Cap Bolts 28 | 0.90 | 78 intb Rocker Case Bolts, L = 55 mm (2.2 in.) as | 090 | 78 intb s Rocker Case Bolts, L = 130 mm (6.1 in.) 98 1.0 | 87 intb s Rocker Case Bolts, L = 30 mm (1.2 in.) 98 1.0 | 87 intb s Rocker Case Bolts, L = 25 mm (1.0 in.) 98 10 | 87 inb s Cylinder Head Bolts (M10), frst torque 25 25 18 s, MO Cylinder Head Bolts (M10), final torque 49 50 36 s Cylinder Head Bolts (M6) 98 10 | 87 intb Water Pipe Mounting Bolts as | 090 | 78 intb Valve Adjusting Screw Locknuts 12 1.2 | 108 in-tb Rocker Shaft Bolts 22 22 16 Rear Rocker Case Clamp Bolt 88 | 090 | 78 intb Camshaft Sprocket Bolts, 12 12 | t06inb} ob Chain Tensioner Cap Bolts 22 22 16 Chain Tensioner Mounting Bolts 88 | 090 | 78 intb Front Cylinder Camshaft Chain Guide Bolt 20 20 15 Position Plate Bolts 88 | 0.90 | 78 intb Intermediate Shaft Chain Guide Bolts 88 | 0.90 | 78 intb Intermediate Shaft Chain Tensioner Bolts 88 | 090 | 78 intb Rear Cylinder Camshaft Chain Guide Bolt 20 20 15 Cylinder Bolts, L = 30 mm (1.2 in.) 98 10 | 87 intb Cylinder Bolts, L = 40 mm (1.6 in.) 98 1.0 | 87 intb Coolant Drain Plugs (Cylinder) 70 | 0.71 | 62 intb Exhaust Pipe Nuts 7 17 13 Exhaust Pipe Cover Bolts 13 13 | 115 intb Muffier Clamp Bolts 15 15 11 Muffler Mounting Bolts 26 29 24 Spark Arrester Mounting Bolts 13 1.3 | 115 intb ‘Converter System Drive Pulley Bolt 93 95 69 Lh Drive Pulley Cover Bolts 125 | 13 | 111 ine Ramp Weight Nuts 70 | 0.71 | 62 intb R Spider 275 28 203, Lh Driven Pulley Nut 93 95 69 R Engine Brake Actuator Mounting Bolts as | 090 | 78 intb s Engine Brake Actuator Cover Bolt 38 | 0.90 | 78 intb s Belt Inspection Opening Cover Bolts 38 | 0.90 | 78 intb Converter Cover Bolts 38 | 090 | 78 intb s Converter Cover Drain Bolt 20 20 15 Joint Duct Botts as_| 090 | 78 intb Engine Lubrication System Oil Filter 75 | 18 13 RPERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener wm kgtm [te | Remarks Oil Pressure Switch 5 15 11 ss Oil Pipe Bolts 88 | 090 | 78 intb Engine Oil Drain Plug 20 20 15 Oil Pressure Relief Valve 15 15 " L il Pump Cover Bolts 88 | 090 | 78 intb Chain Guide Bolt 88 | 090 | 78 intb il Pump Drive Chain Tensioner Bolt 25 25 18 Oil Filter Mounting Bolt 25 25 18 |L(5mm) Plate Bolts 88_| 090 | 78 intb Engine Removal/installation Engine Bracket Pipe Mounting Nuts a5 | 42 31 R Engine Mounting Bolt 601 | 64 44 Engine Mounting Nut 601 | 64 44 R Crankshaft/Transmission Connecting Rod Big End Cap Nuts (KRF7SONAPA/RA/SAITA ~ NCIPCIRCISCIVC) eeu tae a ae Connecting Rod Big End Cap Nuts (KRF7SONDIPDIRDISD) ae . ute Engine Oil Drain Plug 20 20 15 Crankcase Bolts (M8), L = 75 mm (2.95 in.) 20 20 15 s Crankcase Bolts (M8), L = 110 mm (4.33 in.) 20 20 15 s Crankcase Bolt (M8), L = 110 mm (4.33 in.) 20 20 1s | sb) Crankcase Bolts (M6), L = 40 mm (1.57 in.) 98 1.0 | 87 intb Crankcase Bolts (M6), L = 65 mm (2.56 in.) 98 1.0 | 87 intb Bearing Position Plate Screws 49 | 050 | 43 intb L Rear Cylinder Camshaft Chain Guide Bolt 20 20 15 Grip Hold Nut 98 1.0 | 87 inh Tie-rod End Locknut 196 | 20 14 Shift Lever Assembly Nut 196 | 20 14 R Tie-rod End Bolt 98 1.0 | 87 intb Tie-rod End Front Locknut 98 1.0 | 87inb | Lh Tie-rod End Rear Locknut 98 1.0 | 87 intb Tie-rod End Nut 196 | 20 14 R Shift Shaft Lever Bolt 135 | 14 10 Shift Shaft Cover Bolts 88 | 090 | 78 intb Shift Shaft Positioning Bolt 3 32 23 Neutral Position Switch 15 15 1" Reverse Position Switch 15 15 " Shift Shaft Spring Bolt 25 25 18 LB ‘Stopper Mounting Bolts 98 1.0 | 87 intb L Shift Lever Guide Bolt 88 | 090 | 78 intb L Shift Lever Pivot Nut 88 | 090 | 78 intb R Shift Lever Bracket Bolt , L= 25 mm (0.98 in.) 198_| 20 14 L2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener a Shift Lever Bracket Bolts , L = 20 mm (0.79 in.) 196 | 20 14 L Front Tie-rod End 98 1.0 | 87 inb Stopper Spring Bolt 26 27 19 Wheel/Tires Front Axle Nuts 266 | 27.4 196 Front Wheel Nuts no | 12 81 s Rear Wheel Nuts no | 12 81 s Tie-rod End Locknuts 44 45 32 Rear Axle Nuts 266 | 27.4 196 Final Drive (Output Bevel Gears) Rotor Mounting Bolts 12 1.2 | 108 in-tb Output Driven Bevel Gear Housing Bolts 26 27 19 Bevel Gear Bearing Holder Nut 200 | 204 | 148 LB Bearing Holder (M64) 120 | 122 89 L Bearing Holder (M75) 250 | 255 | 184 L Output Shaft Holder Nut 200 | 204 | 148 LB Output Drive Bevel Gear Housing Bolts 26 27 19 oun Bevel Gear Cover Bolt, L = 65 mm ss | oso | ind utp Drive Bevel Gear Cover Bolts, L = 20 mm ae ose aie Forward/Reverse Detecting Sensor Mounting Bolt 149 | 15 4 (Front Final Gear Case) Differential Control Shift Shaft Lever Nut 88 | 0.90 | 78 intb R Differential Shift Cable Holder Bolt 88 | 0.90 | 78 intb Front Final Gear Case ler Cap 29 30 24 Front Final Gear Case Oil Drain Plug 15 15 11 2WD/4WD Shift Cable Holder Bolts, 38 | 0.90 | 78 intb L 2WDI4WD Shift Shaft Cover Bolts 88 | 0.90 | 78 intb L 2WD/4WD Shift Shaft Lever Nut 20 20 15 R Pinion Gear Bearing Holder Nut 200 | 204 | 148 LB Pinion Gear Bearing Holder 250 | 255 | 184 Lo Coupling Nut 35 36 26 R Front Final Gear Case Center Cover Bolts (M8) 24 24 18 L Front Final Gear Case Center Cover Bolts (M10) 49 50 36 L Ring Gear Bolts 87 58 42 iB Front Final Gear Case Left Cover Bolts (M6,35mm)| 88 | 0.90 | 78 inib Front Final Gear Case Left Cover Bolts (M6, 40mm) | 88 | 0.90 | 78 inib Front Final Gear Case Mounting Nuts 905 | 92 67 R Front Final Gear Case Bracket Bolts 905 | 92 67 Differential Shift Cable Locknuts 98 10 | 87 intb 2WVD/4WD Shift Cable Locknuts 44 | 0.45 | 39 intbPERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener wm kgtm [te | Remarks ‘AWD Position Switch 5 15 11 Vacuum Actuator Bracket Bolts 88 | 090 | 78 intb Solenoid Valve Bracket Bolts 88 | 090 | 78 intb Vacuum Actuator Mounting Bolts 88 | 090 | 78 intb (Rear Final Gear Case) Rear Master Cylinder Mounting Bolts Fad 28 20 L Rear Master Cylinder Bleed Valve 78 | 080 | 69intb Rear Final Gear Case Front Cover Bolts 24 24 18 Spring Bracket Bolt 88 | 090 | 78 intb L Rear Final Gear Case Gasket Screws 13° | 0.43 | 12 intb Pinion Gear Bearing Holder 450 | 459 | 332 L Pinion Gear Bearing Holder Nut 200 | 204 | 148 LB Rear Final Gear Case Oil Drain Plug 15 15 1 Rear Final Gear Case Oil Filler Cap 29 30 24 Rear Final Gear Case Right Cover Bolts (M10) 49 50 36 L Rear Final Gear Case Right Cover Bolts (M12) 94 96 69 L Rear Final Gear Case Mounting Nuts 905 | 92 67 R Rear Final Gear Case Bracket Bolts 905 | 92 67 Heat Guard Bolts 88 | 0.90 | 78 intb Brakes Front Master Cylinder Reservoir Cap 3.4 | 0.35 | 30 intb Reservoir Clamp Bolt 62 | 063 | 55 intb Piston Stop Bolt 88 | 090 | 78 intb Brake Pipe Nipples 75 | 18 13 Brake Pipe Joint 75 | 18 13 Brake Hose Banjo Bolts 235 | 24 7 Front Master Cylinder Mounting Bolts 235 | 24 7 Master Cylinder Bolt 235 | 24 7 Push Rod Locknut 72 | 18 13 Parking Brake Pedal Assy Mounting Bolts a5 | 42 3t Front Brake Pad Mounting Bolts gone | nate: 13 Caliper Bleed Valves 78 | 0.80 | 69 inb Brake Hose Clamp Bolts 88 | 0.90 | 78 intb L Caliper Holder Shaft dgane | neta. 13 Brake Caliper Mounting Bolts 33 34 24 L Front Brake Disc Mounting Bolts a5 | 42 3t L Parking Brake Position Switch Screws 04 | 004 | 4 intb Rear Master Cylinder Bleed Valve 78 | 0.80 | 69 intb Rear Master Cylinder Mounting Bolts rag 28 20 L Rear Final Gear Case Front Cover Bolts, 24 24 18 Spring Bracket Bolt 88 | 090 | 78 intb L Rear Final Gear Case Gasket Screws 13° | 0.43 | 12 intb2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener wm kgtm [tee | Remarks ‘Suspension Front Shock Absorber Mounting Nuts 575 | 59 42 R Front Suspension Arm Pivot Nuts 875 | 89 65 R Steering Knuckle Joint Nuts 465 | 47 34 Rear Shock Absorber Mounting Nuts 955 | 97 70 R Rear Suspension Arm Pivot Nuts 875 | 89 65 R Rear Knuckle Mounting Nuts 575 | 59 42 R Stabilizer Joint Nuts 575 | 59 42 R Stabilizer Holder Bolts 315 | 32 23 L ‘Steering Steering Wheel Mounting Nut sa | 55 40 R Steering Knuckle Joint Nuts 45 | 47 34 Main Shaft Mounting Bolts ais | 42 3 Intermediate Shaft Clamp Bolts 2s | 22 7 Steering Gear Assembly Nuts 95 | 97 70 R Tie-rod End Locknuts “4 | 45 32 Tie-rod End Nuts a5 | 42 4 Frame Right and Left Bar Mounting Bolts 98 10 72 Upper Bar Mounting Bolts, 4s | 47 34 Back Bar Mounting Bolts 4s | 47 34 Bottom Guard Bolts 3s | 090 | 78inib Front Guard Bolts 315 | 32 23 Seat Belt Case Mounting Nuts 465 | 47 34 Seat Belt Mounting Bolts ais | 42 4 Seat Belt Buckle Mounting Bolts 45 | 47 34 Seat Belt Bracket Mounting Bolts 45 | 47 34 Seat Plate Bolts as | 090 | 78inb | L Brake Pedal Bracket Mounting Bolts, L = 20 mm @7ein) ‘9 343 | 35 25 L Brake Pedal racket Mounting Bots, L=S0mm(12| 545 | 35 oe Center Bracket Mounting Bolts 22 | 22 16 Right Frame Pipe Mounting Bolts 343 | 35 25 Bracket Bolts a7 | 48 35 Heart Guard Bolts 3s _| 090 | 78inib Electrical System Starter Motor Mounting Bolts as | 090 | 78inib Starter Motor Terminal Locknut 1" 14 | 97 intb Starter Motor Cable Mounting Nut 6s | 069 | 60inib Starter Motor Through Bolts, 50 | 0st | 44inib Starter Motor Clutch Bolts 34 | 35 25 L Left Engine Cover Bolts s9_| oo | szin | LPERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener wm kgtm [te | Remarks Alternator Rotor Bolt 127 | 130 94 Alternator Cover Plugs 75 | 18 13 Crankshaft Sensor Mounting Bolts 59 | 060 | 52intb Alternator Stator Bolts 135 | 14 10 Alternator Cover Bolts, L = 55 mm (2.17 in) 88 | 0.90 | 78 intb Alternator Cover Bolts, L = 30 mm (1.18 in) 88 | 0.90 | 78 intb Breather Plate Screws 29 | 030 | 26 intb L Ignition Coil Mounting Bolts 59 | 060 | 52 intb ‘Spark Plugs 13 13° | 115 intb Vacuum Actuator Bracket Bolts 88 | 0.90 | 78 intb Solenoid Valve Bracket Bolts 88 | 0.90 | 78 intb ECU Mounting Bolts 69 | 0.70 | 61 inib Engine Brake Actuator Mounting Bolts 88 | 0.90 | 78 intb s Engine Brake Actuator Cover Bolt 88 | 0.90 | 78 intb s ForwardiReverse Detecting Sensor Mounting Bolt 149 | 15 1" ‘Speed Sensor Mounting Bolt 88 | 0.90 | 76 intb Reverse Position Switch 15 15 " Neutral Position Switch 15 15 "1 AWD Position Switch 15 15 "1 Water Temperature Sensor 12 1.2. | 106 intb Radiator Fan Assembly Bolts 83 | 0.85 | 73 intb Oil Pressure Switch 15 15 " ss Battery Holder Mounting Nuts 16 16 12 Regulator/Rectifier Mounting Bolts 88 | 0.90 | 78 intb2-12 PERIODIC MAINTENANCE Torque and Locking Agent The tables 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 Trim (in). | Mark of bolt head im a ab 5 (0.20) aT 22-26 0.22 = 0.27 19 ~ 23 in-ib 6 (0.24) oT 12-15 12-15 104 ~ 130 int 6 (0.24) 77 78-98 08-10 69 ~ 87 int 6 (0.24) aT 39-49 04-05 35 ~ 43 nib 8 (031) 7 18 - 22 18-22 13-16 8 (031) aT 10 ~14 10-14 87 ~ 122 inl 10 (0.39) ai 39 44 40~45 29 ~ 33 10 (0.39) aT 20 ~ 24 20~24 14-17 Basic Torque for General Fasteners of Frame Parts Torque Threads dia. mm (in.) Nm kgm fb 5 (0.20) 34~49 0.35 ~ 0.50 25~38 6 (0.24) 59-78 0.60 - 0.80 43-58 8 (031) 14-19 1.40 ~ 1.90 10-13 10 (0.39) 25 - 34 2.60 ~ 3.50 19 ~ 25 12 (0.47) 44 = 61 450 ~ 6.20 33 ~ 45 14 (0.55) 73 ~ 98 7.40 ~ 10.0 54 ~ 72 16 (0.63) 115 ~ 155 115 ~ 16.0 83 ~ 115 18 (071) 165 ~ 225 17.0 ~ 23.0 125 - 165 20 (0.79) 225 ~ 325 23.0 - 33.0 165 ~ 240PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System Throttle Pedal Free Play 5 ~ 10 mm (0.20 ~ 0.39 in.) oe Idle Speed 1100 #50 r/min (rpm) Air Cleaner Element Oil High-quality foam air fitter oil Cooling System Coolant: ‘Type (Recommended) Permanent type of anitfreze (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 4.4 (4.7 US qt) Engine Top End Valve Clearance: Exhaust 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) Intake 0.10 ~ 0.15 mm (0.0039 ~ 0.00589 in.) Converter System Belt Width 30.0 ~ 30.6 mm (1.181 ~ 1.205 in.) 28.6 mm (1.126in.) Belt Deflection 22 ~ 31 mm (0.87 ~ 1.22 in.) (at checking) --- 22 ~ 27 mm (0.87 ~ 1.06 in.) (at adjusting) Actuator Lever Guide Shoe Wear ~~~ 6 mm (0.24 in.) Engine Lubrication System Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, sae MAM or MA2 Viscosity SAE 10W-40 --- 2.4L 2.5 US qt) --- ecm (When filter is not removed) 2.5 L (2.6 US qt) ae (When filter is removed) 2.6 L (2.7 US qt) ae (When engine is completely dry) Wheels/Tires Tire Tread Depth: Front --- 4mm (0.16 in.) Rear --- 4mm (0.16 in.) ‘Standard tire Front 26 x 8,00-12 MAXXIS, M989, Tubeless Rear 26 x 10.00-12 MAXXIS, M990, Tubeless.2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Front Final Gear Case: Gear Case Oil Type API SG, SH, SJ, SL or SM with JASO MA, seat MAM or MA2 Viscosity SAE 10W-40 --- Oil Level Filler opening bottom --- Capacity 0.7 L 0.74 US gt) --- Rear Final Gear Case: Gear Case Oil Type MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC --- FLUID or EXXON HYDRAUL 560 Oil Level Filler opening bottom --- Capacity 1.0 L (1.08 US at) scoala Brakes Brake Fluid! Type DoT 3 --- Brake Pads: Pad Lining Thickness 3.9 mm (0.15 in.) 1mm (0.04 in.) Brake Pedal Brake Pedal Play 2.~ 10 mm (0.08 ~ 0.39 in.) scoala ‘Steering Steering Wheel Free Play }0 ~ 20 mm (0 ~ 0.79 in.) Electrical System Spark Plug Gap Rear Brake Light Switch Timing 10.7 ~ 0.8 mm (0.028 ~ 0.031 in.) JON after 10 mm (0.4 in.) of pedal travel