2001-2007 Kawasaki Mule 3010/3020/3000 (KAF620) OEM Service & Repair Manual

MULE3010 MULE3020 MULE3000 Utility Vehicle Service Manual

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide General Information 1 Fuel System 2 Cooling System 3 Engine Top End 4 Converter System 5 Engine Lubrication System 6 Engine Removal/Installation 7 Engine Bottom End 8 Transmission 9 Wheels/Tires 10 Final Drive 11 Brakes 12 Suspension 13 Steering 14 Frame 15 Electrical System 16 Appendix 17

LIST OF ABBREVIATIONS A ampere(s) lb pounds(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h hour(s) Ω ohm(s) L liter(s) Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1), exhaust emission (2), and evaporative emission (3) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow -by gases are led to the breather chamber through the crankcase. 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. 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. 3. Evaporative Emission Control System The evaporative emission control system for this Mule utility vehicle consists of low permeation fuel hoses. 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 knowingly 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 following its sale and delivery to the ultimate purchaser..." (Continued on next page.)

NOTE ○ The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of de- vices or elements of design in order to perform maintenance. 2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are ex- ceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US Model only) To minimize the noise emissions from this product, Kawasaki has equipped it with effective 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.

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information 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 procedures 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 adversely 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 vehicle 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 maintenance and repair with dates and any new parts installed. How to Use This Manual In preparing this manual, we divided the product into its major systems. These systems be- came the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a sin- gle chapter. 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 Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for exam- ple, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug sec- tion. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE ○ This note symbol indicates points of particular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. 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 specified tightening torque, oil, grease or a locking agent during assembly.

2001-2007 Kawasaki Mule 3010/3020/3000 (KAF620) OEM Service & Repair Manual

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