Utility Vehicle Service Manual

1 MULE 3010 TRANS 4 4. Utility Vehicle Service Manual property of - Not for Resale property of - Not for Resale Quick Reference Guide General Information 1 j Periodic Maintenance 2 j Fuel System 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.

2 Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. property of - Not for Resale property of - Not for Resale MULE 3010 TRANS 4 4. 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 Department/Consumer Products & Machinery 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.

3 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. property of - Not for Resale 2004 Kawasaki Heavy Industries.

4 Ltd., First Edition (1): Nov. 1, 2004 (M). 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) ohm(s).

5 L liter(s). Read OWNER'S Manual before operating. property of - Not for Resale EMISSION CONTROL INFORMATION. To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) 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.

6 Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back 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 a modified carburetor and ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

7 A maintenance free ignition system provides the most favorable ignition timing and helps main- tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere. 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 (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.

8 (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 ". (Continued on next page.). property of - Not for Resale NOTE. The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1.

9 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: of Vehicle components such that the emission standards are ex- ceeded. of replacement parts or accessories which adversely affect the performance or durability of the Vehicle . of components or accessories that result in the Vehicle exceeding the stan- dards. 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 $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. property of - Not for Resale 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.