General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-11

 Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-5

Specifications ......................................................................................................................... 2-12

Special Tools .......................................................................................................................... 2-14

Periodic Maintenance Procedures.......................................................................................... 2-15

Fuel System......................................................................................................................... 2-15

Throttle Pedal Free Play Inspection.................................................................................. 2-15

Throttle Pedal Play Adjustment......................................................................................... 2-15

Choke Knob Free Play Inspection .................................................................................... 2-16

Choke Knob Play Adjustment ........................................................................................... 2-16

Idle Speed Inspection ....................................................................................................... 2-16

Idle Speed Adjustment...................................................................................................... 2-16

Fuel System Cleanliness Inspection ................................................................................. 2-17

Air Cleaner Element Cleaning and Inspection .................................................................. 2-17

Air Cleaner Draining.......................................................................................................... 2-18

Fuel Hoses and Connections Inspection .......................................................................... 2-18

Fuel Hose Replacement ................................................................................................... 2-19

Cooling System.................................................................................................................... 2-19

Radiator Cleaning ............................................................................................................. 2-19

Water Hoses and Connections Inspection........................................................................ 2-20

Coolant Change................................................................................................................ 2-20

Engine Top End ................................................................................................................... 2-24

Valve Clearance Inspection .............................................................................................. 2-24

Valve Clearance Adjustment............................................................................................. 2-26

Spark Arrester Cleaning.................................................................................................... 2-26

Converter System................................................................................................................ 2-27

Converter Drive Belt Wear Inspection............................................................................... 2-27

Drive Belt Deflection Inspection ........................................................................................ 2-29

Converter Drive Belt Deflection Adjustment...................................................................... 2-30

Actuator Lever (Engine Brake Control Lever) Assembly Inspection ................................. 2-30

Engine Lubrication System.................................................................................................. 2-31

Engine Oil Change............................................................................................................ 2-31

Oil Filter Replacement ...................................................................................................... 2-32

Wheels/Tires........................................................................................................................ 2-32

Tire Inspection .................................................................................................................. 2-32

Wheels Nuts Tightness Inspection.................................................................................... 2-33

Final Drive............................................................................................................................ 2-33

Differential Shift Lever Play Inspection ............................................................................. 2-33

Differential Shift Lever Play Adjustment............................................................................ 2-33

Front Final Gear Case Oil Change ................................................................................... 2-33

Rear Final Gear Case Oil Change.................................................................................... 2-34

Brakes.................................................................................................................................. 2-35

Brake Fluid Level Inspection............................................................................................. 2-35

Brake Fluid Change .......................................................................................................... 2-35

Brake Pedal Play Inspection ............................................................................................. 2-37

Brake Master Cylinder Cup and Dust Seal Replacement................................................. 2-37

Rear Brake Master Cylinder Cup, O-ring and Boot Replace ............................................ 2-38

Brake Hose and Pipe Inspection....................................................................................... 2-40

Brake Hose Replacement................................................................................................. 2-41

Parking Brake Pedal Inspection........................................................................................ 2-43

 2-2 PERIODIC MAINTENANCE

Front Brake Pad Wear Inspection..................................................................................... 2-43

Front Brake Caliper Piston Seal and Dust Seal Replacement.......................................... 2-44

Rear Brake Plates Replacement....................................................................................... 2-45

Steering ............................................................................................................................... 2-45

Steering Inspection ........................................................................................................... 2-45

Steering Joint Dust Boot Inspection.................................................................................. 2-46

Frame .................................................................................................................................. 2-46

Seat Belt Inspection .......................................................................................................... 2-46

Electrical System................................................................................................................. 2-47

Spark Plug Cleaning/Inspection........................................................................................ 2-47

Spark Plug Gap Inspection ............................................................................................... 2-47

Brake Light Switch Inspection........................................................................................... 2-47

Brake Light Timing Adjustment ......................................................................................... 2-48

Joint Boots Inspection.......................................................................................................... 2-48

Front Axle/Steering Knuckle Joint Boots Inspection ......................................................... 2-48

Front Propeller Shaft Joint Boots Inspection..................................................................... 2-48

Tie-rod End Boots Inspection............................................................................................ 2-48

Rear Propeller Shaft Joint Boots Inspection ..................................................................... 2-49

Rear Axle/Stabilizer Joint Boots Inspection ...................................................................... 2-49

General Lubrication ............................................................................................................. 2-49

Lubrication ........................................................................................................................ 2-49

Cables.................................................................................................................................. 2-50

Inspection.......................................................................................................................... 2-50

Bolts and Nuts Tightening.................................................................................................... 2-51

Tightness Inspection ......................................................................................................... 2-51

 Fuel System

Table of Contents

Exploded View................................... 3-2

Specifications .................................... 3-6

Special Tools ..................................... 3-7

Throttle Pedal and Cable................... 3-8

Throttle Pedal Free Play

Inspection.................................. 3-8

Throttle Pedal Free Play

Adjustment ................................ 3-8

Full Throttle Pedal Position

Adjustment ................................ 3-8

Throttle Pedal Removal ............... 3-8

Throttle Pedal Installation ............ 3-9

Throttle Cable Installation ............ 3-9

Throttle Cable Lubrication and

Inspection.................................. 3-10

Choke Knob and Cable ..................... 3-11

Choke Knob Free Play Inspection 3-11

Choke Knob Free Play

Adjustment ................................ 3-11

Choke Cable Removal ................. 3-11

Choke Cable Installation .............. 3-12

Choke Cable Lubrication and

Inspection.................................. 3-12

Carburetor ......................................... 3-13

Idle Speed Inspection .................. 3-13

Idle Speed Adjustment................. 3-13

Pilot Screw Adjustment ................ 3-13

Service Fuel Level Inspection...... 3-14

Service Fuel Level Adjustment .... 3-16

Carburetor Synchronization

Inspection.................................. 3-16

Carburetor Synchronization

Adjustment ................................ 3-17

Fuel System Cleanliness

Inspection.................................. 3-17

Carburetor Removal..................... 3-17

Carburetor Installation.................. 3-19

Carburetor Disassembly .............. 3-19

Carburetor Assembly ................... 3-21

Carburetor Separation ................. 3-22

Carburetor Joining ....................... 3-22

Carburetor Cleaning..................... 3-23

Carburetor Inspection .................. 3-24

Air Cleaner......................................... 3-26

Air Cleaner Element Removal...... 3-26

Air Cleaner Element Installation... 3-27

Air Cleaner Element Cleaning and

Inspection.................................. 3-27

Air Cleaner Housing and Duct

Removal.................................... 3-28

Air Cleaner Housing and Duct

Installation ................................. 3-28

Fuel Tank........................................... 3-30

Fuel Tank Removal ...................... 3-30

Fuel Tank Installation ................... 3-30

Fuel Tank Cleaning ...................... 3-31

Fuel Pump ......................................... 3-32

Fuel Pump Removal .................... 3-32

Fuel Pump Installation ................. 3-32

Fuel Pump Inspection .................. 3-33

Fuel Filter........................................... 3-34

Fuel Filter Removal...................... 3-34

Fuel Filter Installation................... 3-34

Fuel Filter Inspection.................... 3-34

 Cooling System

Table of Contents

Exploded View........................................................................................................................ 4-2

Coolant Flow Chart................................................................................................................. 4-4

Specifications ......................................................................................................................... 4-6

Special Tools & Sealant.......................................................................................................... 4-7

Coolant ................................................................................................................................... 4-8

Coolant Deterioration Inspection....................................................................................... 4-8

Coolant Level Inspection................................................................................................... 4-8

Coolant Draining ............................................................................................................... 4-8

Coolant Filling ................................................................................................................... 4-8

Pressure Testing ............................................................................................................... 4-9

Water Pump............................................................................................................................ 4-10

Water Pump Cover Removal ............................................................................................ 4-10

Water Pump Cover Installation ......................................................................................... 4-10

Water Pump Impeller Removal ......................................................................................... 4-10

Water Pump Impeller Installation ...................................................................................... 4-10

Water Pump Impeller Inspection....................................................................................... 4-11

Water Pump Leakage Inspection...................................................................................... 4-11

Mechanical Seal Replacement ......................................................................................... 4-11

Radiator.................................................................................................................................. 4-13

Radiator Removal ............................................................................................................. 4-13

Radiator Installation .......................................................................................................... 4-14

Radiator Fan Removal...................................................................................................... 4-14

Radiator Fan Installation ................................................................................................... 4-15

Radiator Inspection ........................................................................................................... 4-15

Radiator Cleaning ............................................................................................................. 4-15

Radiator Cap Inspection ................................................................................................... 4-15

Thermostat ............................................................................................................................. 4-17

Thermostat Removal......................................................................................................... 4-17

Thermostat Installation...................................................................................................... 4-17

Thermostat Inspection ...................................................................................................... 4-17

Radiator Fan Switch ............................................................................................................... 4-18

Radiator Fan Switch Removal .......................................................................................... 4-18

Radiator Fan Switch Installation ....................................................................................... 4-18

Radiator Fan Switch Inspection ........................................................................................ 4-18

Water Temperature Switch ..................................................................................................... 4-19

Water Temperature Switch Removal ................................................................................ 4-19

Water Temperature Switch Installation ............................................................................. 4-19

Water Temperature Switch Inspection .............................................................................. 4-19

 Engine Top End

Table of Contents

Exploded View................................... 5-2

Specifications .................................... 5-8

Special Tools and Sealant ................. 5-11

Camshaft Chain Tensioner ................ 5-13

Camshaft Chain Tensioner

Removal.................................... 5-13

Camshaft Chain Tensioner

Installation ................................. 5-13

Rocker Case...................................... 5-15

Rocker Case Removal................. 5-15

Rocker Case Installation .............. 5-16

Rocker Arm Removal................... 5-17

Rocker Arm Installation................ 5-18

Rocker Arm Inspection................. 5-18

Rocker Shaft Diameter

Measurement ............................ 5-18

Camshaft ........................................... 5-19

Camshaft Removal ...................... 5-19

Camshaft Installation ................... 5-19

Camshaft Assembly..................... 5-20

Cam Wear Inspection .................. 5-20

Camshaft Bearing Wear

Inspection.................................. 5-21

KACR Inspection.......................... 5-22

KACR Removal............................ 5-22

KACR Installation......................... 5-23

Camshaft Chain Removal............ 5-23

Camshaft Chain Installation ......... 5-24

Camshaft Chain Guide Wear

Inspection.................................. 5-27

Cylinder Head.................................... 5-28

Cylinder Compression

Measurement ............................ 5-28

Cylinder Head Removal ............... 5-29

Cylinder Head Installation ............ 5-29

Cylinder Head Cleaning............... 5-30

Cylinder Head Warp Inspection ... 5-30

Valves ................................................ 5-31

Valve Clearance Inspection ......... 5-31

Valve Clearance Adjustment........ 5-31

Valve Removal............................. 5-31

Valve Installation .......................... 5-31

Valve Guide Removal .................. 5-31

Valve Guide Installation ............... 5-32

Valve-to-Guide Clearance

Measurement ............................ 5-32

Valve Seat Inspection .................. 5-33

Valve Seat Repair (Valve

Lapping) .................................... 5-33

Cylinder and Piston ........................... 5-38

Cylinder Removal......................... 5-38

Piston Removal............................ 5-38

Cylinder, Piston Installation.......... 5-38

Cylinder Wear Inspection............. 5-40

Piston Wear Inspection ................ 5-40

Piston/Cylinder Clearance

Inspection.................................. 5-40

Piston Ring, Piston Ring Groove

Wear Inspection ........................ 5-41

Piston Ring Groove Width

Inspection.................................. 5-41

Piston Ring Thickness Inspection 5-41

Piston Ring End Gap Inspection.. 5-42

Exhaust System................................. 5-43

Spark Arrester Cleaning............... 5-43

Muffler and Exhaust Pipe

Removal.................................... 5-43

Exhaust System Inspection.......... 5-45

Muffler and Exhaust Pipe

Installation ................................ 5-45

 Converter System

Table of Contents

Exploded View........................................................................................................................ 6-2

Specifications ......................................................................................................................... 6-6

Special Tools .......................................................................................................................... 6-7

Torque Converter Cover ......................................................................................................... 6-9

Torque Converter Cover Removal .................................................................................... 6-9

Torque Converter Cover Installation ................................................................................. 6-9

Torque Converter Cover Disassembly .............................................................................. 6-10

Actuator Lever (Engine Brake Control Lever) Assembly Inspection ................................. 6-10

Torque Converter Cover Assembly................................................................................... 6-11

Drive Belt................................................................................................................................ 6-13

Drive Belt Removal ........................................................................................................... 6-13

Drive Belt Installation ........................................................................................................ 6-13

Drive Belt Deflection Inspection ........................................................................................ 6-13

Drive Belt Deflection Adjustment ...................................................................................... 6-13

Drive Belt Inspection ......................................................................................................... 6-13

Drive Pulley ............................................................................................................................ 6-14

Drive Pulley Removal........................................................................................................ 6-14

Drive Pulley Disassembly ................................................................................................. 6-14

Drive Pulley Inspection ..................................................................................................... 6-15

Spider Shoe Side Clearance Inspection/Adjustment ........................................................ 6-17

Drive Pulley Assembly ...................................................................................................... 6-18

Drive Pulley Installation..................................................................................................... 6-20

Driven Pulley .......................................................................................................................... 6-22

Driven Pulley Removal...................................................................................................... 6-22

Driven Pulley Disassembly ............................................................................................... 6-22

Driven Pulley Inspection ................................................................................................... 6-23

Driven Pulley Assembly .................................................................................................... 6-24

Driven Pulley Installation................................................................................................... 6-26

 Engine Lubrication System

Table of Contents

Exploded View........................................................................................................................ 7-2

Specifications ......................................................................................................................... 7-4

Special Tools & Sealant.......................................................................................................... 7-5

Engine Oil Flow Chart............................................................................................................. 7-6

Engine Oil and Oil Filter.......................................................................................................... 7-7

Oil Level Inspection........................................................................................................... 7-7

Engine Oil Change............................................................................................................ 7-7

Oil Filter Change............................................................................................................... 7-7

Oil Screen Removal.......................................................................................................... 7-7

Oil Screen Cleaning .......................................................................................................... 7-8

Oil Pressure Measurement ............................................................................................... 7-8

Oil Pressure Relief Valve........................................................................................................ 7-10

Oil Pressure Relief Valve Removal ................................................................................... 7-10

Oil Pressure Relief Valve Installation ................................................................................ 7-10

Oil Pressure Relief Valve Inspection................................................................................. 7-10

Oil Pump................................................................................................................................. 7-11

Oil Pump Removal............................................................................................................ 7-11

Oil Pump Installation ......................................................................................................... 7-11

Oil Pipe ................................................................................................................................... 7-13

Oil Pipe Removal .............................................................................................................. 7-13

Oil Pipe Installation ........................................................................................................... 7-14

 Engine Removal/Installation

Table of Contents

Exploded View........................................................................................................................ 8-2

Engine Removal/Installation ................................................................................................... 8-4

Engine Removal................................................................................................................ 8-4

Engine Installation............................................................................................................. 8-6

Crankshaft/Transmission

Table of Contents

Exploded View........................................................................................................................ 9-2

Specifications ......................................................................................................................... 9-6

Special Tools and Sealant ...................................................................................................... 9-8

Crankcase .............................................................................................................................. 9-9

Crankcase Disassembly ................................................................................................... 9-9

Crankcase Assembly ........................................................................................................ 9-9

Crankshaft/Connection Rod ................................................................................................... 9-13

Crankshaft Removal ......................................................................................................... 9-13

Crankshaft Installation ...................................................................................................... 9-13

Connecting Rod Removal................................................................................................. 9-13

Connecting Rod Installation .............................................................................................. 9-13

Crankshaft/Connecting Rod Cleaning............................................................................... 9-14

Connecting Rod Bend Inspection ..................................................................................... 9-14

Connecting Rod Twist Inspection...................................................................................... 9-14

Connecting Rod Big End Side Clearance Inspection........................................................ 9-15

Connecting Rod Big End Bearing/Crankpin Wear Inspection........................................... 9-15

Crankshaft Runout Inspection........................................................................................... 9-17

Crankshaft Main Bearing/Journal Wear Inspection........................................................... 9-17

Transmission .......................................................................................................................... 9-18

Shift Lever Removal.......................................................................................................... 9-18

Shift Lever Installation....................................................................................................... 9-19

Transmission Removal ..................................................................................................... 9-23

Transmission Installation .................................................................................................. 9-24

Shift Fork Bending Inspection ........................................................................................... 9-26

Shift Fork/Gear and Shifter Groove Wear Inspection ....................................................... 9-26

Transmission and Shift Mechanism Inspection................................................................. 9-27

Ball Bearing, Needle Bearing, and Oil Seal............................................................................ 9-29

Ball and Needle Bearing Replacement ............................................................................. 9-29

Ball and Needle Bearing Wear Inspection ........................................................................ 9-29

Oil Seal Inspection ............................................................................................................ 9-29

 Wheels/Tires

Table of Contents

Exploded View........................................................................................................................ 10-2

Specifications ......................................................................................................................... 10-4

Special Tools .......................................................................................................................... 10-5

Wheel Alignment .................................................................................................................... 10-6

Toe-in Adjustment ............................................................................................................. 10-6

Wheels (Rims)........................................................................................................................ 10-8

Wheel Removal................................................................................................................. 10-8

Wheel Installation.............................................................................................................. 10-8

Wheel (Rim) Inspection..................................................................................................... 10-8

Wheel (Rim) Replacement................................................................................................ 10-9

Tires ....................................................................................................................................... 10-10

Tire Removal..................................................................................................................... 10-10

Tire Installation.................................................................................................................. 10-10

Tire Inspection .................................................................................................................. 10-11

Front Hub ............................................................................................................................... 10-12

Front Hub Removal........................................................................................................... 10-12

Front Hub Installation........................................................................................................ 10-12

Front Hub Disassembly/Assembly.................................................................................... 10-13

Rear Hub ............................................................................................................................... 10-14

Rear Hub Removal ........................................................................................................... 10-14

Rear Hub Installation ........................................................................................................ 10-14

Rear Hub Disassembly/Assembly..................................................................................... 10-15

 Final Drive

Table of Contents

Exploded View........................................................................................................................ 11-3

Specifications ......................................................................................................................... 11-10

Special Tools .......................................................................................................................... 11-11

Output Bevel Gears................................................................................................................ 11-13

Output Drive Bevel Gear Removal.................................................................................... 11-13

Output Drive Bevel Gear Installation................................................................................. 11-13

Output Drive Bevel Gear Disassembly ............................................................................. 11-14

Output Drive Bevel Gear Assembly .................................................................................. 11-16

Output Driven Bevel Gear Removal.................................................................................. 11-16

Output Driven Bevel Gear Installation............................................................................... 11-17

Output Driven Bevel Gear Disassembly ........................................................................... 11-17

Output Driven Bevel Gear Assembly ................................................................................ 11-18

Output Bevel Gears Adjustment ....................................................................................... 11-19

Bevel Gears Inspection..................................................................................................... 11-23

Front Propeller Shaft .............................................................................................................. 11-24

Front Propeller Shaft Removal.......................................................................................... 11-24

Front Propeller Shaft Installation....................................................................................... 11-24

Front Propeller Shaft Inspection ....................................................................................... 11-26

Front Axle ............................................................................................................................... 11-27

Front Axle Removal .......................................................................................................... 11-27

Front Axle Installation ....................................................................................................... 11-27

Front Axle Joint Boot Inspection ....................................................................................... 11-27

Front Axle Joint Boot Replacement .................................................................................. 11-27

Front Final Gear Case............................................................................................................ 11-34

Front Final Gear Case Oil Level Inspection ...................................................................... 11-34

Front Final Gear Case Oil Change ................................................................................... 11-34

Differential Shift Lever Play Inspection ............................................................................. 11-34

Differential Shift Lever Play Adjustment............................................................................ 11-34

Differential Shift Lever Removal ....................................................................................... 11-34

Differential Shift Lever Installation .................................................................................... 11-35

Differential Shift Cable Installation .................................................................................... 11-35

Differential Shift Cable Lubrication.................................................................................... 11-36

Differential Shift Cable Inspection..................................................................................... 11-36

2WD/4WD Shift Cable Removal ....................................................................................... 11-36

2WD/4WD Shift Cable Installation .................................................................................... 11-37

2WD/4WD Vacuum Actuator Removal ............................................................................. 11-38

2WD/4WD Vacuum Actuator Installation .......................................................................... 11-39

2WD/4WD Shift Cable Lubrication.................................................................................... 11-40

2WD/4WD Shift Cable Inspection ..................................................................................... 11-40

Front Final Gear Case Removal ....................................................................................... 11-40

Front Final Gear Case Installation .................................................................................... 11-41

Front Final Gear Case Disassembly................................................................................. 11-42

Front Final Gear Case Coupling Inspection...................................................................... 11-46

Front Final Gear Case Assembly...................................................................................... 11-46

Ring Gear Disassembly .................................................................................................... 11-54

Ring Gear Assembly......................................................................................................... 11-54

LSD Clutch Torque Inspection .......................................................................................... 11-55

Pinion Gear Unit Disassembly .......................................................................................... 11-55

Pinion Gear Unit Assembly............................................................................................... 11-56

Front Final Bevel Gear Adjustment................................................................................... 11-57

 11-2 FINAL DRIVE

Front Final Gear Case Backlash Adjustment.................................................................... 11-60

Front Final Gear Case Tooth Contact Adjustment ............................................................ 11-61

Bevel Gear Inspection....................................................................................................... 11-64

Differential Gear Inspection .............................................................................................. 11-64

Rear Propeller Shaft ............................................................................................................... 11-65

Rear Propeller Shaft Removal .......................................................................................... 11-65

Rear Propeller Shaft Installation ....................................................................................... 11-65

Rear Propeller Shaft Inspection ........................................................................................ 11-67

Rear Axle................................................................................................................................ 11-68

Rear Axle Removal ........................................................................................................... 11-68

Rear Axle Installation ........................................................................................................ 11-68

Rear Axle Joint Boot Inspection........................................................................................ 11-68

Rear Axle Joint Boot Replacement................................................................................... 11-69

Rear Final Gear Case............................................................................................................. 11-75

Rear Final Gear Case Oil Level Inspection....................................................................... 11-75

Rear Final Gear Case Oil Change.................................................................................... 11-75

Rear Final Gear Case Removal........................................................................................ 11-75

Rear Final Gear Case Installation..................................................................................... 11-77

Rear Final Gear Case Disassembly.................................................................................. 11-77

Rear Final Gear Case Right Cover Assembly .................................................................. 11-80

Rear Final Gear Case Front Cover Assembly .................................................................. 11-80

Rear Final Gear Case Assembly ...................................................................................... 11-81

Pinion Gear Unit Disassembly .......................................................................................... 11-85

Pinion Gear Unit Assembly............................................................................................... 11-86

Rear Final Bevel Gear Adjustment ................................................................................... 11-86

Rear Final Gear Case Backlash Adjustment .................................................................... 11-89

Tooth Contact Adjustment................................................................................................. 11-90

Bearing and Oil Seal............................................................................................................... 11-92

Ball or Needle Bearing Inspection..................................................................................... 11-92

Oil Seal Inspection ............................................................................................................ 11-93

 Brakes

Table of Contents

Exploded View........................................................................................................................ 12-2

Specifications ......................................................................................................................... 12-6

Brake Fluid ............................................................................................................................. 12-7

Front Brake Fluid Recommendation ................................................................................. 12-7

Front Brake Fluid Level Inspection ................................................................................... 12-7

Front Brake Fluid Change................................................................................................. 12-7

Brake Line Air Bleeding .................................................................................................... 12-8

Brake Pedal and Master Cylinder........................................................................................... 12-10

Brake Pedal Play Inspection ............................................................................................. 12-10

Brake Pedal Removal ....................................................................................................... 12-10

Brake Pedal Installation .................................................................................................... 12-10

Front Master Cylinder Removal ........................................................................................ 12-11

Front Master Cylinder Installation ..................................................................................... 12-11

Front Master Cylinder Disassembly/Assembly ................................................................. 12-11

Front Master Cylinder Inspection ...................................................................................... 12-12

Rear Master Cylinder Removal......................................................................................... 12-12

Rear Master Cylinder Installation...................................................................................... 12-12

Rear Master Cylinder Disassembly/Assembly.................................................................. 12-12

Rear Master Cylinder Inspection....................................................................................... 12-13

Calipers .................................................................................................................................. 12-14

Front Brake Caliper Removal............................................................................................ 12-14

Front Brake Caliper Installation......................................................................................... 12-14

Front Brake Caliper Disassembly ..................................................................................... 12-14

Front Brake Caliper Assembly .......................................................................................... 12-14

Front Brake Caliper Piston and Cylinder Damage Inspection........................................... 12-15

Front Brake Caliper Holder Shaft Wear Inspection........................................................... 12-15

Brake Pads............................................................................................................................. 12-16

Front Brake Pad Removal................................................................................................. 12-16

Front Brake Pad Installation.............................................................................................. 12-16

Front Brake Pad Wear Inspection..................................................................................... 12-16

Brake Discs ............................................................................................................................ 12-17

Front Brake Disc Cleaning ................................................................................................ 12-17

Front Brake Disc Removal................................................................................................ 12-17

Front Brake Disc Installation ............................................................................................. 12-17

Front Brake Disc Wear Inspection .................................................................................... 12-17

Front Brake Disc Runout Inspection ................................................................................. 12-17

Brake Hoses and Pipes.......................................................................................................... 12-18

Brake Hose and Pipe Inspection....................................................................................... 12-18

Brake Hose Replacement................................................................................................. 12-18

Parking Brake Pedal and Cables............................................................................................ 12-19

Parking Brake Pedal Inspection........................................................................................ 12-19

Parking Brake Pedal Removal.......................................................................................... 12-19

Parking Brake Pedal Installation ....................................................................................... 12-19

Parking Brake Cable Removal.......................................................................................... 12-19

Parking Brake Cable Installation....................................................................................... 12-20

Parking Brake Cable Lubrication ...................................................................................... 12-20

Internal Wet Brake.................................................................................................................. 12-21

Internal Wet Brake Disassembly....................................................................................... 12-21

Internal Wet Brake Assembly............................................................................................ 12-21

 Suspension

Table of Contents

Exploded View........................................................................................................................ 13-2

Specifications ......................................................................................................................... 13-6

Special Tools .......................................................................................................................... 13-7

Shock Absorbers .................................................................................................................... 13-8

Front Shock Absorber Preload Adjustment....................................................................... 13-8

Front Shock Absorber Removal........................................................................................ 13-8

Front Shock Absorber Installation..................................................................................... 13-8

Front Shock Absorber Inspection...................................................................................... 13-9

Front Shock Absorber Scrapping...................................................................................... 13-9

Rear Shock Absorber Preload Adjustment ....................................................................... 13-9

Rear Shock Absorber Removal ........................................................................................ 13-10

Rear Shock Absorber Installation ..................................................................................... 13-10

Rear Shock Absorber Inspection ...................................................................................... 13-11

Rear Shock Absorber Scrapping ...................................................................................... 13-11

Suspension Arms ................................................................................................................... 13-12

Front Suspension Arm Removal....................................................................................... 13-12

Front Suspension Arm Installation .................................................................................... 13-13

Front Suspension Arm Disassembly................................................................................. 13-14

Front Suspension Arm Assembly...................................................................................... 13-14

Rear Suspension Arm Removal........................................................................................ 13-15

Rear Suspension Arm Installation..................................................................................... 13-16

Rear Suspension Arm Disassembly ................................................................................. 13-16

Rear Suspension Arm Assembly ...................................................................................... 13-17

Stabilizer Removal............................................................................................................ 13-17

Stabilizer Installation ......................................................................................................... 13-18

Stabilizer Joint Inspection ................................................................................................. 13-18

Rear Knuckle Removal ..................................................................................................... 13-18

Rear Knuckle Installation .................................................................................................. 13-19

Rear Knuckle Disassembly ............................................................................................... 13-19

Rear Knuckle Assembly.................................................................................................... 13-20

Bearing and Oil Seal............................................................................................................... 13-21

Ball Bearing Inspection ..................................................................................................... 13-21

Oil Seal Inspection ............................................................................................................ 13-21

 Steering

Table of Contents

Exploded View........................................................................................................................ 14-2

Specifications ......................................................................................................................... 14-4

Special Tools .......................................................................................................................... 14-5

Steering Wheel and Main Shaft Assembly ............................................................................. 14-6

Steering Wheel Position Adjustment................................................................................. 14-6

Steering Wheel Free Play Inspection................................................................................ 14-6

Steering Wheel Centering................................................................................................. 14-6

Steering Wheel Removal .................................................................................................. 14-6

Steering Wheel Installation ............................................................................................... 14-7

Steering Shafts Removal .................................................................................................. 14-7

Steering Shafts Installation ............................................................................................... 14-8

Steering Gear Assembly......................................................................................................... 14-9

Steering Gear Assembly Removal.................................................................................... 14-9

Steering Gear Assembly Installation................................................................................. 14-9

Tie-rod Length Adjustment................................................................................................ 14-11

Steering Joint Dust Boot Inspection.................................................................................. 14-11

Steering Knuckles................................................................................................................... 14-12

Steering Knuckle Removal................................................................................................ 14-12

Steering Knuckle Installation............................................................................................. 14-12

Knuckle Bearing Removal................................................................................................. 14-13

Knuckle Bearing Installation.............................................................................................. 14-13

 Frame

Table of Contents

Exploded View................................... 15-2

Seat and Seat Belts........................... 15-14

Seat Removal .............................. 15-14

Seat Installation ........................... 15-14

Seat Disassembly ........................ 15-14

Seat Assembly............................. 15-15

Seat Belt Removal ....................... 15-16

Seat Belt Installation .................... 15-17

Control Panel..................................... 15-18

Control Panel Removal................ 15-18

Control Panel Installation ............. 15-19

Glove Compartment Removal...... 15-20

Glove Compartment Installation... 15-21

Fenders ............................................. 15-22

Front Fender Removal................. 15-22

Front Fender Installation .............. 15-23

Rear Fender Removal.................. 15-23

Rear Fender Installation............... 15-23

Rear Flap Removal...................... 15-24

Rear Flap Installation ................... 15-24

Cargo Bed ......................................... 15-25

Cargo Bed Removal..................... 15-25

Cargo Bed Installation.................. 15-25

Cargo Bed Disassembly .............. 15-26

Cargo Bed Assembly ................... 15-29

Bars ................................................... 15-32

Right and Left Bars Removal....... 15-32

Right and Left Bars Installation .... 15-32

Covers ............................................... 15-35

Engine Upper Cover Removal ..... 15-35

Engine Upper Cover Installation .. 15-35

Center Cover Removal ................ 15-36

Center Cover Installation ............. 15-36

Side Cover Removal.................... 15-36

Side Cover Installation ................. 15-38

Seat Lower Cover Removal......... 15-38

Seat Lower Cover Installation...... 15-39

Seat Lower Right Plate Removal. 15-39

Seat Lower Right Plate

Installation ................................. 15-40

Seat Lower Left Plate Removal ... 15-40

Seat Lower Left Plate Installation 15-40

Right and Left Brackets Removal 15-40

Right and Left Brackets

Installation ................................. 15-41

Center Bracket Removal.............. 15-41

Right Frame Pipe Removal.......... 15-42

Right Frame Pipe Installation....... 15-42

Center Bracket Installation........... 15-43

Left Cover Removal ..................... 15-43

Left Cover Installation .................. 15-43

Guards............................................... 15-44

Front Guard Removal .................. 15-44

Front Guard Installation ............... 15-44

Front Bottom Guard Removal ...... 15-44

Front Bottom Guard Installation ... 15-45

Middle Bottom Guard Removal.... 15-45

Middle Bottom Guard Installation. 15-45

Engine Bottom Guard Removal ... 15-45

Engine Bottom Guard Installation 15-46

Rear Bottom Guard Removal....... 15-46

Rear Bottom Guard Installation.... 15-46

Floorboard ......................................... 15-47

Floorboard Removal .................... 15-47

Floorboard Installation ................. 15-50

 Electrical System

Table of Contents

Parts Location.................................... 16-3

Exploded View................................... 16-6

Specifications .................................... 16-12

Wiring Diagram.................................. 16-14

Special Tools ..................................... 16-16

Precautions........................................ 16-17

Electrical Wiring................................. 16-18

Wiring Inspection ......................... 16-18

Battery ............................................... 16-19

Battery Removal .......................... 16-19

Battery Installation ....................... 16-20

Battery Activation (CA Model)...... 16-21

Precautions.................................. 16-23

Interchange.................................. 16-23

Charging Condition Inspection..... 16-24

Refreshing Charge ...................... 16-24

Charging System............................... 16-27

Alternator Cover Removal............ 16-27

Alternator Cover Installation......... 16-28

Alternator Rotor Removal ........... 16-29

Alternator Rotor Installation ......... 16-30

Alternator Stator Removal............ 16-31

Alternator Stator Installation......... 16-31

Regulator/Rectifier Output

Voltage Inspection..................... 16-31

Alternator Inspection .................... 16-32

Regulator/Rectifier Removal ........ 16-33

Regulator/Rectifier Installation ..... 16-33

Regulator/Rectifier Inspection...... 16-33

Ignition System.................................. 16-35

Spark Plug Removal .................... 16-35

Spark Plug Installation ................. 16-35

Spark Plug Cleaning/Inspection... 16-35

Spark Plug Gap Inspection .......... 16-35

Ignition Coil Removal................... 16-35

Ignition Coil Installation ................ 16-36

Ignition Coil Inspection................. 16-37

Ignition Coil Primary Peak Voltage

Inspection.................................. 16-38

Crankshaft Sensor Removal........ 16-38

Crankshaft Sensor Installation ..... 16-39

Crankshaft Sensor Inspection...... 16-39

Crankshaft Sensor Peak Voltage

Inspection.................................. 16-39

Alternator Rotor Inspection .......... 16-40

Ignition Timing Test ...................... 16-40

Electric Starter System...................... 16-43

Starter Motor Removal................. 16-43

Starter Motor Installation.............. 16-43

Starter Motor Disassembly........... 16-44

Starter Motor Assembly ............... 16-45

Brush Inspection .......................... 16-47

Commutator Cleaning and

Inspection.................................. 16-47

Armature Inspection..................... 16-47

Brush Lead Inspection ................. 16-48

Right-hand End Cover Inspection 16-48

Starter Relay Inspection............... 16-48

Starter Circuit Relay Inspection ... 16-48

Starter Motor Clutch Removal...... 16-50

Starter Motor Clutch Installation... 16-51

Starter Motor Clutch Inspection ... 16-51

Torque Limiter Inspection............. 16-51

Lighting System................................. 16-52

Headlight Beam Vertical

Adjustment ................................ 16-52

Headlight Bulb Replacement ....... 16-52

Tail/Brake Light Bulb

Replacement............................. 16-54

Radiator Fan System......................... 16-57

Radiator Fan Circuit Inspection.... 16-57

Radiator Fan Motor Inspection..... 16-57

Radiator Fan Breaker Inspection . 16-57

Radiator Fan Breaker Installation 16-58

Actuator Control System.................... 16-59

Engine Brake Actuator Removal.. 16-59

Engine Brake Actuator

Installation ................................. 16-59

Actuator Control System Outline.. 16-60

Engine Brake Actuator Inspection 16-60

Speed Sensor Circuit Inspection.. 16-61

Controller Unit Inspection............. 16-62

Forward/Reverse Detecting

Sensor Inspection ..................... 16-63

Carburetor Heater System................. 16-65

Air Temperature Sensor

Inspection.................................. 16-65

Carburetor Heater Inspection....... 16-66

2WD/4WD Solenoid Valve................. 16-67

2WD/4WD Solenoid Valve

Inspection.................................. 16-67

Switches and Sensor......................... 16-69

Brake Light Switch Adjustment .... 16-69

Radiator Fan Switch Inspection ... 16-69

Water Temperature Switch

Inspection.................................. 16-70

Speed Sensor Removal/Installation

............................................ 16-70

Speed Sensor Inspection............. 16-71

Switch Inspection......................... 16-71

 Appendix

Table of Contents

Troubleshooting Guide ........................................................................................................... 17-2

Cable, Wire, and Hose Routing .............................................................................................. 17-7

Through 17-42

MODEL APPLICATION

Year Model Beginning Frame No.

2008 KRF750A8F JKARFDA1□8B500001

2008 KRF750B8F JKARFDB1□8B500001

□:This digit in the frame number changes from one machine to another.