Factory Service Repair Manual For Kawasaki MULE 3010 DIESEL 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: 470
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No

Model

Kawasaki ATV MULE 3010 DIESEL
KAF950B1
KAF950B2

Contents

– General Information
Before Servicing
Model Identification
General Specifications
Technical Information Fuel Injection System Components
Unit Conversion Table
– Periodic Maintenance
Periodic Maintenance Chart
Torque And Locking Agent
Periodic Maintenance Procedures
Fuel System
Throttle Pedal Free Play
Idle Speed Inspection
Fuel Hoses And Connections
Fuel Hoses Replacement
Fuel Filter Element Replacement
Fuel Filter Water Draining
Cooling System
Radiator Cleaning
Radiator Hose And Connection
Coolant Change
Cooling Fan Belt Inspection
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning
Converter System
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Converter Driven Pulley Shoe
Converter Air Cleaner Element
Cleaning/Inspection
Engine Lubrication System
Engine Oil And/Or Oil Filter
Change
Oil Filter Removal
Oil Filter Installation
Transmission
Transmission Oil Change
Wheels/Tires
Wheels Nuts Tightness Inspection
Tire Wear Inspection
Final Drive
Front Final Gear Case Oil Change
Brakes
Brake Fluid Level Inspection
Brake Fluid Change
Brake Pedal Play Inspection
Brake Master Cylinder Cup And
Dust Seal Replacement
Brake Hose And Pipe Inspection
Brake Hose And Pipe
Brake Wear Inspection
Brake Wheel Cylinder Assembly
Parking Brake Lever Inspection
Steering
Steering Inspection
Steering Joint Dust Boot
Electrical System
Electrolyte Level Inspection
Electrolyte Specific Gravity
Charging Condition Inspection
Brake Light Switch Inspection
General Lubrication
Bolts, Nuts, And Fasteners
Tightness Inspection
– Fuel System
Throttle Pedal And Cable
Throttle Pedal Free Play Inspection
Throttle Pedal Free Play Adjustment
Full Throttle Pedal Position Adjustment
Throttle Cable Installation
Throttle Cable Lubrication
Throttle Cable Inspection
Fuel Injection Nozzle
Fuel Injection Nozzle Removal
Fuel Injection Nozzle Installation
Fuel Injection Nozzle Inspection
Fuel Injection Pump
Idle Speed Inspection
Idle Speed Adjustment
Maximum Engine Speed Inspection
Maximum Engine Speed Adjustment
Fuel Injection Pipe Removal
Fuel Injection Pipe Installation
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Fuel Injection Pump Timing Inspection
Fuel Injection Pump Inspection And Repair
Fuel Injection Pump Troubleshooting
Air Cleaner
Air Cleaner Element Cleaning
Air Cleaner Housing Removal
Air Cleaner Housing Dust And/Or Water Inspection
Fuel Filter
Fuel Filter Removal
Fuel Filter Installation
Fuel Filter Cartridge Replacement
Water Draining
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning/Inspection
– Cooling System
Coolant
Coolant Level Inspection
Coolant Draining
Coolant Filling
Water Pump
Water Pump Removal
Water Pump Installation
Water Pump Inspection
Radiator And Radiator Fan
Radiator Removal
Radiator Inspection
Radiator Cleaning
Radiator Cap Inspection
Thermostat
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Hoses And Pipes
Hose And Pipe Installation
Hose Inspection
Radiator Fan Switch, Coolant Temperature Warning Light Switch
Radiator Fan Switch Removal
Coolant Temperature Warning Light Switch Removal
Radiator Fan Switch, Coolant Temperature Warning Light Switch Installation
Radiator Fan Switch, Coolant Temperature Warning Light Switch Inspection
– Engine Top End
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Warp
Rocker Shaft And Rocker Arm
Rocker Arm Components Removal
Rocker Arm Components Installation
Rocker Arm Components Disassembly
Rocker Arm Components Assembly
Rocker Arm/Shaft Wear
Valve Lifters
Valve Lifter Removal
Valve Lifter Installation
Valve Lifter Inspection
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve Seat Inspection
Valve Seat Repair
Valve Spring Free Length
Valve Head Thickness
Valve Stem Diameter
Valve Guide Inspection
Measuring Valve/Guide Clearance
Valve Stem Cap Inspection
Exhaust Pipe And Muffler
Exhaust Pipe Removal
Muffler Removal
Exhaust Pipe And Muffler Installation
Exhaust Pipe And Muffler Inspection
Spark Arrester Cleaning
– Converter System
Air Cleaner
Air Cleaner Housing Removal
Air Cleaner Element Removal
Air Cleaner Element
Cleaning/Inspection
Torque Converter
Drive And Driven Pulley Removal
Drive And Driven Pulley
Torque Converter Inner Cover
Torque Converter Case Removal
Torque Converter Case
Torque Converter
Torque Converter Outer Cover
Torque Converter Outer Cover
Torque Converter Inner Cover
Torque Converter Inner Cover
Torque Converter Case Removal
Torque Converter Case
Drive Belt
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Spider Shoe Side Clearance
Drive Pulley Assembly
Bushing Installation
Driven Pulley
Driven Pulley Removal
Driven Pulley Disassembly
Driven Pulley Inspection
Converter Driven Pulley Shoe
Bushing Installation
Driven Pulley Assembly
Driven Pulley Width Inspection
Driven Pulley Installation
– Engine Lubrication System
Engine Oil Flow Chart
Engine Oil And Oil Filter
Oil Level Inspection
Oil And/Or Filter Change
Oil Filter Removal
Oil Filter Installation
Oil Pan And Oil Strainer
Oil Pan And Oil Strainer Removal
Oil Pan And Oil Strainer Installation
Oil Strainer Cleaning/Inspection
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Pump Inspection
Relief Valve
Relief Valve Removal
Relief Valve Installation
Relief Valve Inspection
Oil Pressure Measurement
Oil Pressure Measurement
Oil Pressure Switch
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Oil Nozzle
Oil Nozzle Installation
– Engine Removal/Installation
– Crankshaft/Crankcase
Timing Gear Case
Timing Gear Case Removal
Timing Gear Case Installation
Timing Gear Case Cover Oil Seal
Timing Gear Inspection
Camshaft
Camshaft Removal
Camshaft Installation
Camshaft Inspection
Crankshaft And Connecting Rods
Connecting Rod Removal
Connecting Rod Installation
Crankshaft Removal
Crankshaft Installation
Connecting Rod Big End Side
Clearance
Connecting Rod Inspection
Crankshaft Inspection
Crankshaft Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Wear
Crankshaft Main Bearing Insert/Journal Wear
End Plate
End Plate Removal
End Plate Installation
Oil Seal Retainer
Oil Seal Replacement
Pistons And Crankcase
Piston Removal
Piston Installation
Crankcase Removal
Crankcase Warp
Crankcase Wear
Piston Diameter
Piston/Cylinder Clearance
Cylinder Boring, Honing
Camshaft Bearing Replacement
Camshaft Plug Replacement
Piston Ring And Ring Groove Wear
Piston Ring End Gap
Piston Ring Thickness
Piston And Piston Pin Wear
– Transmission
Transmission Oil
Transmission Oil Level Inspection
Transmission Oil Change
Transmission Case
Transmission Case Removal
Transmission Case Installation
Transmission Case Splitting
Transmission Case Assembly
Transmission And Shift Mechanism
Transmission Shift Cable Adjustment
Transmission Shift Cable Inspection
Transmission Removal
Transmission Installation
Transmission And Shift
Mechanism Inspection
Hi/Low Gears And Shift Mechanism
Hi/Low Shift Cable Adjustment
Hi/Low Shift Cable Inspection
Hi/Low Gear And Shift Mechanism
Hi/Low Gear And Shift Mechanism
Hi/Low Gear And Shift Mechanism
Shift Mechanism
Shift Cable Adjustment
Shift Cable Lubrication
Shift Cable Inspection
Shift Mechanism
Shift Mechanism
Shift Mechanism
Inspection
Differential Gears And Shiftn Mechanism
Differential Shift Cable Adjustment
Differential Shift Cable Lubrication
Differential Shift Cable Inspection
Differential Shift Mechanism
Differential Shift Mechanism Installation
Differential Shift Mechanism Inspection
Differential Gear Removal
Differential Gear Installation
Differential Gear Inspection
Bearings And Oil Seal
Bearing Replacement
Ball Bearing Inspection
Needle Bearing Inspection
Oil Seal Inspection
Transmission Sectional Figure
– Wheels/Tires
Wheel Alignment
Toe In Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tires
Tire Removal
Tire Installation
Tire Wear Inspection
– Final Drive
Front Final Gear Case
Front Final Gear Case Oil Level Inspection
Front Final Gear Case Oil Change
Front Final Gear Case Removal
Front Final Gear Case Installation
Front Final Gear Case Disassembly
Front Final Gear Case Assembly
Differential Unit And Ring Gear Disassembly
Differential Unit And Ring Gear Assembly
Lsd Clutch Torque Inspection
Lsd Clutch Plate Inspection
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Front Final Bevel Gear Adjustment
Bevel Gear Inspection
Differential Gear Inspection
Tapered Roller Bearing Inspection
Ball Bearing Inspection
Oil Seal Inspection
Bevel Gear Case
Bevel Gear Case Removal
Bevel Gear Case Installation
Bevel Gear Case Disassembly
Bevel Gear Case Assembly
Drive Bevel Gear Removal
Drive Bevel Gear Installation
Bevel Gear Adjustment
Bevel Gear Inspection
Ball Bearing/Oil Seal Inspection
Damper Inspection
Propeller Shafts
Propeller Shaft Removal
Propeller Shaft Installation
Propeller Shaft Inspection
Drive Shaft And Axles
Front Axle Removal
Front Axle Installation
Rear Drive Shaft And Axle Removal
Rear Drive Shaft And Axle Installation
Drive Shaft And Axle Inspection
Dust Boot Inspection
Front Axle Joint Boot Replacement
Ball Bearing Inspection
Grease Seal Inspection
– Brakes
Brake Fluid
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Air Bleeding
Brake Pedal And Master Cylinder
Brake Pedal Play Inspection
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly/Assembly
Master Cylinder Inspection
Brake Hoses 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 Assy Removal
Brake Panel Assy Installation
Brake Panel Disassembly
Brake Panel Assembly
Wheel Cylinder Removal/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 Lubrication/Inspection
– Suspension
Struts And Rear Shock Absorbers
Strut (Front Shock Absorber) Removal
Strut (Front Shock Absorber) Installation
Strut Spring Replacement
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Shock Absorber Inspection
Front Suspension Arms
Front Suspension Arm Removal
Front Suspension Arm Installation
Front Suspension Arm Inspection
Leaf Springs And Dampers
Leaf Spring Removal
Leaf Spring Installation
Leaf Spring Inspection
– Steering
Steering Wheel And Main Shaft Assembly
Steering Wheel Position Adjustment
Steering Wheel Free Play Inspection
Steering Wheel Centering
Steering Wheel And Steering Shaft Removal
Steering Wheel And Main Shaft Installation
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 And Seat Belts
Seat Removal
Seat Installation
Seat Belt Removal
Seat Belt Installation
Control Panel
Control Panel Removal
Glove Compartment Removal
Front Cargo Compartment
Front Cargo Hood Removal
Front Cargo Compartment Removal
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Front And Rear Bars
Front Bar Removal
Front Bar Installation
Rear Bar Removal
Rear Bar Installation
Cargo Bed Latch Position Inspection
Cargo Bed Latch Position Adjustment
Front Fender Assembly
Front Guard Removal
Front Cover Removal
Front Fender Removal
Radiator Side Cover Removal
Radiator Side Cover Installation
Radiator Side Cover Flap Removal
Floor Center Panel Removal
Rear End Sub Frame
Rear End Sub Frame Removal
Rear End Sub Frame Installation
– Electrical System
Wiring Diagram
Specifications
Special Tools And Sealant
Parts Location
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Level Inspection
Electrolyte Specific Gravity Inspection
Charging Condition Inspection
Initial Charging
Ordinary Charging
Battery Testing Chart
Alternator
Alternator Removal
Alternator Installation
Alternator Disassembly
Alternator Assembly
Alternator Operational Inspection
Stator Coil Inspection
Rotor Coil Inspection
Slip Ring Cleaning
Slip Ring Diameter
Carbon Brush Length
Rectifier Inspection
Regulator Inspection
Alternator Ball Bearing Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Carbon Brush Inspection
Yoke Inspection
Brush Plate Inspection
Commutator Cleaning/Inspection
Armature Inspection
Pinion Gear Inspection
Starter Switch Inspection
Starter Circuit Relay Inspection
Preheating System
Glow Plug Removal
Glow Plug Installation
Glow Plug Inspection
Preheating Timer Inspection
Glow Plug Relay Inspection
Glow Plug Relay Installation
Fuel Cut Solenoid
Fuel Cut Solenoid
Fuel Cut Solenoid Inspection
Radiator Fan
Radiator Fan Circuit Inspection
Radiator Fan Motor Inspection
Lighting System
Headlight Beam Adjustment
Headlight Bulb Replacement
Tail/Brake Light Replacement
Reverse Light Switch Installation (Option)
Switches
Brake Light Switch Inspection
Radiator Fan Switch Inspection
Coolant Temperature Warning
Light Switch Inspection
Switch Inspection
Fuses
Fuse Removal
Fuse Installation
Fuse Inspection
– Appendix
Troubleshooting Guide
Cable, Wires, And Hose Routing