Factory Service Repair Manual For Kawasaki MULE 3010 TRANS 4×4 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: 412
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No

Model

Kawasaki ATV MULE 3010 TRANS 4×4
KAF620J1
KAF620K1

Contents

– General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
– Periodic Maintenance
Torque And Locking Agent
Periodic Maintenance Procedures
Fuel System
Throttle Pedal Free Play
Throttle Pedal Free Play
Full Throttle Pedal Position
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness
Fuel Filter Inspection
Intake Chamber Water Draining
External Carburetor Mechanism Cleaning
Fuel Hoses And Connections
Fuel Hoses Replacement
Air Cleaner Element Cleaning
Air Cleaner Housing Dust And/Or
Water Inspection
Cooling System
Radiator Cleaning
Radiator Hose And Connection
Coolant Draining
Coolant Filling
Coolant Filter Inspection
Converter System
Drive Belt Inspection
Converter Driven Pulley Shoe
Air Cleaner Element
Cleaning/Inspection
Converter Dust Or Water Draining
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning
Engine Lubrication
Oil And/Or Filter Change
Oil Filter Removal
Oil Filter Installation
Transmission
Transmission Oil Change
Wheels/Tires
Wheels Nuts Tightness
Tire Inspection
Final Drive
Front Final Gear Case Oil
Change
Brakes
Brake Fluid Level Inspection
Brake Fluid Changing
Brake Pedal Free Play
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 Travel
Steering
Steering Wheel Free Play
Inspection
Steering Joint Dust Boot
Inspection
Frame
Seat Belt Inspection
Electrical System
Brake Light Switch Adjustment
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
General Lubrication
Bolts, Nuts, And Fasteners
Tightness Inspection
– Fuel System
Exploded View
Throttle Pedal And Cable
Throttle Pedal Free Play
Throttle Pedal Free Play
Full Throttle Pedal Position
Throttle Cable Installation
Throttle Cable Lubrication
Throttle Cable Inspection
Governor Link Mechanism
Control Panel Assembly Removal
Control Panel Assembly
Governor Arm And Throttle Link
Governor Arm Installation
Governor Assembly Removal
Governor Assembly Installation
Governor Assembly Inspection
Throttle Link Lever Installation
Maximum Engine Speed
Choke Cable
Choke Cable Free Play
Choke Cable Free Play
Choke Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Carburetor
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Coolant Filter Cleaning
Coolant Valve Inspection
Air Cleaner
Air Cleaner Element Cleaning
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Air Cleaner Housing Dust And/Or
Water Inspection
Fuel Pump And Fuel Filter
Fuel Pump And Fuel Filter
Fuel Pump Installation
Fuel Filter Installation
Fuel Filter Inspection
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning/Inspection
– Cooling System
Sealant
Flow Chart
Coolant
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pump
Water Pump Removal
Water Pump Installation
Water Pump Inspection
Radiator And Radiator Fan
Radiator Removal
Radiator Inspection
Radiator Cleaning
Radiator Cap
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, 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 Disassembly And Assembly (Valve Mechanism Removal And Installation)
Cylinder Head Warp
Valves
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Seat Inspection
Valve Seat Repair
Valve Spring Free Length
Valve Head Thickness
Valve Stem Bend
Valve Stem Diameter
Valve Guide Inside Diameter
Measuring Valve/Guide Clearance (Wobble Method)
Rocker Arm/Shaft Wear
Rocker Arm Push Rod 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
Torque Converter Removal
Torque Converter Installation
Torque Converter Case Removal
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Drive Belt Inspection
Drive Pulley
Drive Pulley Disassembly
Drive Pulley Assembly
Spider/Wear Guide Clearance Adjustment
Drive Pulley Inspection
Bushing Installation
Driven Pulley
Driven Pulley Disassembly
Driven Pulley Assembly
Driven Pulley Inspection
Bushing 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 Pump And Relief Valve
Oil Pump And Relief Valve Removal
Oil Pump And Relief Valve Installation
Oil Pump And Relief Valve Inspection
Oil Screen
Oil Screen Removal
Oil Screen Installation
Oil Screen Cleaning/Inspection
Oil Pressure Switch
Oil Pressure Switch Removal
Oil Pressure Switch Installation
– Engine Removal/Installation
– Engine Bottom End
Crankcase Cover
Crankcase Cover Removal
Crankcase Cover Installation
Camshaft And Tappets
Camshaft Removal
Camshaft Installation
Camshaft Inspection
Cam Wear
Camshaft Bearing/Journal Wear
Cylinders And Pistons
Piston Removal
Piston Installation
Piston Ring, Piston Ring Groove Wear
Piston Ring End Gap
Cylinder Inside Diameter
Piston Diameter
Boring, Honing
Crankshaft And Connecting Rods
Connecting Rod Removal
Connecting Rod Installation
Crankshaft Removal
Crankshaft Installation
Crankshaft Cleaning
Connecting Rod Bend/Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Wear
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Breather Valve
Breather Valve Removal
Breather Valve Installation
Breather Valve Inspection
– Transmission
Special Tools And Sealant
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 And Hi/Low Shift
Cables Installation
Shift Lever Position Inspection
Shift Lever Position Adjustment
Transmission Shift Cable
Transmission Removal
Transmission Installation
Transmission And Shift
Mechanism Inspection
Hi/Low Gears And Shift Mechanism
Hi/Low Shift Cable Installation
Hi/Low Shift Cable Inspection
Hi/Low Gear And Shift Mechanism Removal
Hi/Low Gear And Shift Mechanism Installation
Hi/Low Gear And Shift Mechanism Inspection
Shift Mechanism
Shift Cable
Adjustment
Shift Mechanism Removal
Shift Mechanism Inspection
Differential Gears And Shift Mechanism
Differential Shift Cable Adjustment
Differential Shift Cable Lubrication
Differential Shift Cable Inspection
Differential Shift Mechanism Removal
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 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 Inspection
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 Changing
Brake Line Air Bleeding
Brake Pedal And Master Cylinder
Brake Pedal Free Play Adjustment
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly
Master Cylinder 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 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 Lubrication
Parking Brake Cable 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
Steering Joint Dust Boot Inspection
Steering Knuckles
Steering Knuckle Removal
Steering Knuckle Installation
– Frame
Seat And Seat Belts
Front Seat Removal
Front Seat Installation
Rear Seat Removal
Rear 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, Center And Rear Bars
Front Bar Removal
Front Bar Installation
Rear Bar Removal
Rear Bar Installation
Center Bar Removal
Center Bar Installation
Cargo Bed Latch Position Inspection
Cargo Bed Latch Position Adjustment
Front Fender Assembly
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
Battery
Battery Removal
Battery Installation
Battery Activation
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Rotor And Stator Removal
Alternator Rotor And Stator Installation
Charging System Operational Inspection
Stator Coil Resistance
Regulator/Rectifier Inspection
Ignition System
Spark Plug Removal/Installation
Spark Plug Gap Inspection
Spark Plug Cleaning/Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Ignition Coil Primary Peak Voltage
Inspection
Pickup Coil Removal
Pickup Coil Inspection
Pickup Coil Peak Voltage Inspection
Ignition System 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
Fuel Pump And Relay
Fuel Pump Operational Inspection
Fuel Pump Relay Internal
Resistance
Radiator Fan
Radiator Fan Circuit Inspection
Radiator Fan Motor Inspection
Lighting System
Headlight Beam Adjustment
Headlight Bulb Replacement
Tail/Brake Light Replacement
Switches
Brake Light Switch Adjustment
Switch Inspection
Radiator Fan Switch Inspection
Coolant Temperature Warning
Light Switch Inspection
Fuses
Fuse Removal
Fuse Installation
Fuse Inspection
Electrical Wiring
Wiring Inspection
Wiring Diagram
– Appendix
Troubleshooting Guide
Cable, Wire, And Hose Routing