Kawasaki MULE 1000 Service Manual ATV

$9.95

Factory Service Repair Manual For Kawasaki MULE 1000 ATV. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 215
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No

Model

Kawasaki ATV MULE1000
KAF450B1-

Contents

– Quick Reference Guide
– Foreword
– General Information
– Fuel System
Sealant
Throttle Pedal and Cable
Throttle Pedal Play Adjustment
Throttle Cable Inspection
Throttle Cable Lubrication
Choke Cable
Choke Cable Play Adjustment
Choke Cable Inspection
Choke Cable Lubrication
Carburetors
Idle Speed Adjustment
Carburetor Synchronization
Fuel Level Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Air Cleaners
Air Cleaner Element Removal
Air Cleaner Removal
Air Cleaner Installation
Air Cleaner Element Cleaning
Air Cleaner Element Inspection
Fuel Filter
Fuel Filter Removal
Fuel Filter Installation
Fuel Filter Inspection
Fuel Pump
Fuel Pump Removal
Fuel Pump Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Tank Inspection
Snorkel Kit (Optional Parts)|
– Cooling System
Coolant Flow Chart
Sealant
Coolant
Coolant Level Inspection
Coolant Inspection
Coolant Change (Draining And Filling)
Mechanical Seal Inspection (Visual Leak Inspection)
Cooling System Pressure Test
Cooling System Flushing
Radiator And Fan
Radiator And Fan Removal
Radiator And Fan Installation
Radiator Inspection
Radiator Cleaning
Radiator And Thermostat Caps
Radiator And Thermostat Cap Removal
Radiator And Thermostat Cap Installation
Thermostat Cap Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Water Pump
Water Pump Disassembly
Water Pump Assembly
Pump Impeller Inspection
Mechanical Seal Inspection
Hoses And Pipes
Hose And Pipe Removal
Hose And Pipe Installation
Hose Inspection
Radiator Fan Switch And Coolant Temperature Switch
Switch Removal
Switch Installation
– Engine Top ENd
Exploded View
Specifications
Special Tools
Sealant
Cylinder Head Cover
Removal
Installation
Camshaft Chain Tensioner
Removal
Installation
Camshafts And Sprockets
Camshaft Removal
Camshaft Installation (Including Chain Timing Procedure)
Camshaft Sprocket Installation
Cam Height Measurement
Camshaft Runout
Camshaft Bearing Oil
Clearance Inspection
Camshaft Chain And Guides
Camshaft Chain Removal
Top Chain Guide Removal
Top Chain Guide Installation
Rear Chain Guide Removal
Rear Chain Guide Installation
Front Chain Guide Removal
Front Chain Guide Installation
Camshaft Chain Wear
Camshaft Chain Guides Wear
Rocker Arms And Shafts
Removal
Installation
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Cylinder Head
Removal
Cylinder Compression Measurement
Cylinder Head Warp
Cylinder Head Cleaning
Carburetor Holders
Installation
Valves
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve Face Contact Inspection
Valve Seat Outside Diameter
Valve Seat Width Inspection
Valve Seat Repair (Valve Lapping)
Measuring ValveToguide Clearance (Wobble Method)
Cylinder And Pistons
Cylinder Removal
Cylinder Installation
Piston Removal
Piston Installation
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Piston Ring And Ring Groove Wear
Piston Ring End Gap
Exhaust Pipe And Muffler (Including Spark Arrester)
Removal
Installation
Spark Arrester Cleaning
Exhaust System Inspection
– Belt Drive Torque Converter
Converter Cover
Removal
Installation
Belt
Drive Pulley
Bushing And Splined Portion Inspection
Sheaves Surface Inspection
Pulley Cover Bushing Inspection
Wear Guide Inspection
Ramp Weight INspection
Roller Inspection
Spring Free Length Inspection
Driven Pulley
Bushing And Splined Portion Inspection
Sheaves Surface Inspection
Ramp Cap Inspection
Spring Free Length Inspection
Wear Shoe Inspection
Air Cleaner (See Fuel System)
– Engine Lubrication System
Engine Oil Flow Chart
Specifications
Special Tools
Sealant
Engine Oil And Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Removal
Oil Filter Installation
Oil Pump
Oil Pressure Measurement
Relief Valve And Oil Screen
Relief Valve Installation
Oil Screen Cleaning And Inspection
Oil Pressure Switch (See Electrical System)
– Engine Removal/Installation
Engine Removal/Installation
Engine Removal
Engine Installation
Engine Separation
Crankcase And Transmission Case Separation
Crankcase And Transmission Case Assembly
Engine Bottom End/Crankshaft
Crankcase
Splitting
Crankshaft/Connecting Rods
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft Main Bearing Insert/Journal Wear
Crankshaft Runout
Crankshaft Side Clearance
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Wear
Balancer
Balancer Shaft Bearing Insert/Journal Wear
Balancer Gear Inspection
Left Engine Cover
Starter Motor Clutch
Starter Motor Clutch Inspection
Starter Motor Chain And Sprockets
Starter Motor Chain Wear
– Transmission/Final Drive
Shift Lever And Cable
Cable Removal
Cable Installation
Shift Lever Removal
Shift Lever Installation
Shift Cable Adjustment
Shift Cable Lubrication
Shift Cable Inspection
External Shift Mechanism
Transmission Case
Splitting
Transmission Shafts
Transmission Disassembly
Transmission Assembly
Shift Fork Bend
Shift Fork/Shifter Groove Wear
Shift Fork Guide Pin/
Shift Drum Groove Wear
Gear Dog Damage
Differential Shift Mechanism
Shift Lever Case Removal
Shift Lever Case Installation
Shifter And Shift Fork Removal
Shifter And Shift Fork Installation
Differential Cable Adjustment
Differential Cable Lubrication
Differential Cable Inspection
Shifter And Shift Fork Inspection
Differential Gears
Differential Gear Inspection
Final Drive Shafts
Drive Shaft Removal
Drive Shaft Installation
Drive Shaft Bearing Replacement
Drive Shaft Inspection
Drive Shaft Ball Joint Rubber
Boot Inspection
Rubber Boot Replacement
Oil Seals
– Wheels Taires
Wheel Alignment
Toe In Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tires
Tire Removal
Tire Installation
Tire Inspection
Front Wheel Bearings And Grease Seals
Front Wheel Bearing Removal
Front Wheel Bearing Installation
Front Wheel Bearing Inspection
Grease Seal Inspection
– Brakes
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Changing
Brake Line Air Bleeding
Brake Pedal And Master Cylinder
Brake Pedal Play Adjustment
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection
Brake Hose And Pipes
Brake Hose And Pipe Inspection
Brake Hose And Pipe Replacement
Brake Drums
Brake Drum Removal
Brake Drum Installation
Brake Drum Wear
Brake Panel Assemblies
Brake Panel Removal
Brake Panel Installation
Wheel Cylinder Assembly
Wheel Cylinder Inspection
Brake Shoe Lining Wear
Brake Shoe Spring Inspection
Parking Brake Lever And Cables
Parking Brake Lever Travel Adjustment
Parking Brake Cable Inspection
Parking Brake Cable Lubrication
– Suspension
Struts And Shock Absorbers
Strut (Front Shock Absorber) Removal
Strut (Front Shock Absorber) Installation
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Shock Absorber Inspection
Suspension Arms
Front Suspension Arm Removal
Front Suspension Arm Installation
Rear Suspension Arm Removal
Rear Suspension Arm Installation
Suspension Arm Inspection
– Steering
Steering Wheel And Main Shaft Assembly
Steering Wheel Free Play Inspection
Steering Wheel And Main Shaft Removal
Steering Wheel And Main Shaft Installation
Steering Wheel Centering
Steering Gear Assembly
Steering Gear Assembly Removal
Steering Gear Assembly Installation
Steering Gear Preload Adjustment
Tie Rod Length Adjustment
Dust Boot Inspection
Steering Knuckles
Steering Knuckle Removal
Steering Knuckle Installation
– Frame
Seat
Seat Removal
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Front And Rear Bar Components
Front Bar Component Removal
Front Bar Component Installation
Rear Bar Component Removal
Rear Bar Component Installation
Front Fender Assembly
Front Fender Upper Removal
Front Fender Upper Installation
Front Fender Lower Removal
Front Fender Lower Installation
Front Fender Inner Upper Removal
Front Fender Inner Left And Right Removal
Front Fender Inner Left And Right Installation
– Electrical System
Exploded View
Part Location
Wiring Diagram
Specifications
Special Tools
Sealant
Precautions
Battery
Precautions
Electrolyte Level Inspection
Battery Condition
Attery Initial Charging
Battery Ordinary Charging
Battery Test Charging
Charging System
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Charging System
Operational Inspection
Stator Coil Resistance
Regulator/Rectifier Inspection
Ignition System
Ignition Coil Installation
Spark Plug Removal
Spark Plug Installation
Pickup Coil Removal/Installation
Ic Igniter Inspection
Ignition Coil Inspection
Spark Plug Cleaning And Inspection
Spark Plug Gap
Pickup Coil Inspection
Alternator Rotor
Projection Inspection
Speed Sensor Inspection
Warning Buzzer Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Carbon Brush Length
Brush Spring Inspection
Brush And Lead Assembly Inspection
Brush Plate Inspection
Commutator Cleaning And Inspection
Armature Inspection
Starter Motor Relay Inspection
Starter Circuit Relay Inspection
Fuel Pump And Relay
Fuel Pomp Operation Test
Relay Internal Resistance
Radiator Fan Circuit
Radiator Fan Circuit Inspection
Fan Motor Inspection
Lighting System
Headlight Beam Adjustment
Bulb Replacement
Diode Inspection
Switches
Brake Light Switch Adjustment
Switch Inspection
Fuses
Fuse Inspection
Electrical Wiring
Wiring Inspection
– Appendix
Trouble Shooting Guide
General Lubrication
Lubrication
Nut, Bolt, And Fastener Tightness
Tightness Inspection
Unit Conversion Table