Kawasaki MULE 600/610 4×4 Repair Service Manual 2005

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This workshop repair service manual PDF download for the MULE 600 / MULE 610 4×4 Kawasaki Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

MULE 610 4×4
MULE 600

Year Model 
Beginning Frame No.

2005 KAF400-A1 
JK1AFEA1□5B500001

2005 KAF400-B1 
JK1AFEB1□5B500001
JK1AF400BBB600001

2005 KAF400-C1 
JK1AFEC1□5B500001


TABLE OF CONTENTS :

General Information 
Periodic Maintenance 
Fuel System 
Engine Top End 
Converter System 
Engine Lubrication System 
Engine Removal/Installation 
Engine Bottom End 
Transmission 
Wheels/Tires 
Final Drive 
Brakes 
Suspension 
Steering 
Frame 
Electrical System 
Appendix


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1349-01
Total Pages : 411


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 desires 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. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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tables
    LIST OF ABBREVIATIONS
    Units of Mass
    Units of Volume
    Units of Force
    Units of Length
    Units of Torque
    Units of Pressure
    Units of Speed
    Units of Power
    Basic Torque for General Fasteners of Engine Parts
    Basic Torque for General Fasteners of Frame Parts
    Throttle Pedal Free Play
    Idle Speed
    Idle Speed
    Valve Clearance (when cold)
    Belt Width
    Belt Deflection
    shims
    Wear Shoe Width
    Engine Oil
    Transmission Oil
    Tire Tread Depth
    Standard Tire
    Front Final Gear Case Oil
    Brake Pedal Free Play
    Brake Drum Inside Diameter
    Brake Shoe Lining thickness
    Parking Brake Lever Travel
    Steering Wheel Free Play
    Spark Plug Gap
    Specific Gravity
    Brake Light Switch Timing
    Idle Speed
    Choke Knob Free Play
    Cylinder Compression
    Rocker Arm Push Rod Runout
    Cylinder Head Warp
    Valve Seating Surface Outside Diameter
    Valve Seating Surface Width Standard
    Valve Spring Free Length
    Valve Head Thickness
    Valve Stem Bend
    Valve Stem Diameter
    Valve Guide Inside Diameter 
    Valve/Guide Clearance (Wobble Method)
    Driven Pulley
    Drive Pulley
    Cover Bushing Inside Diameter [A]
    Sheave Bushing Inside Diameter [A]
    Spring Free Length [A]
    Shoe Side Clearance
    Sheave Bushing Inside Diameter
    Spring Free Length [A]
    Inner and Outer Rotor Clearance
    Outer Rotor Outside Diameter
    Outer Rotor Thickness
    Pump Housing Inside Diameter
    Pump Housing Depth
    Pump Shaft Outside Diameter
    Pump Shaft Bearing Inside Diameter 
    Relief Valve Spring Free Length
    Cam Lobe Height
    Crankcase Side Camshaft Journal Diameter
    Crankcase Cover Side Camshaft Journal Diameter
    Camshaft Bearing Inside Diameter (Crankcase)
    Camshaft Bearing Inside Diameter (Crankcase Cover)
    Piston Ring/Groove Clearance
    Piston Ring Thickness
    Piston Ring End Gap
    Piston Pin Outside Diameter
    Piston Pin Hole Inside Diameter
    Connecting Rod Small End Inside Diameter
    Piston Diameter
    Cylinder Inside Diameter
    Cylinder Bore Out-Round
    Connecting Rod Bend
    Connecting Rod Twist
    Connecting Rod Big End Width
    Crankpin Width
    Connecting Rod Big End Inside Diameter
    Crankpin Outside Diameter
    Crankshaft Runout
    Crankcase Side Crankshaft Main Journal Diameter
    Crankshaft Main Bearing Inside Diameter (Crankcase Side)
    Balancer Shaft Journal Diameter
    Balancer Shaft Bearing Inside Diameter (Crankcase)
    Balancer Shaft Bearing Inside Diameter (Crankcase cover)
    Shift Fork Ear Thickness
    Shifter Groove Width [A]
    Reverse Chain 20-Link Length [B]
    Shifter Block Outside Diameter
    Shifter Groove Width
    Shift Shaft Pin Diameter [A]
    Shifter Groove Width [B]
    Toe-in of Front Wheels
    Tie-rod Length (distance between flange end and locknut)
    Maximum Tire Air Pressure (to seat beads when cold)
    Tire Air Pressure (when cold)
    LSD Clutch Torque
    Outside Friction Plate Thickness [A]
    Inside Friction Plate Thickness [B]
    Bevel Gear Backlash
    Bevel Gear Backlash
    Drive Gear Shims [4]
    Standard Length of Assembling:
    Standard Length of Assembling:
    Recommended Brake Fluid
    Spring Action
    Battery Troubleshooting Guide
    Regulator/Rectifier Output Voltage 
    Stator Coil Resistance 
    Ignition Coil Air Gap
    Ignition Coil Winding Resistance
    Testing Solenoid
    Testing Starter Motor
    Carbon Brush Length
    Commutator Groove Depth
    Commutator Outside Diameter
    Commutator Runout
    Armature Winding Resistance
    Commutator to Shaft Resistance
    Positive Brush to Ground Resistance
    Negative Brush to Ground Resistance
    Testing Relay
    Oil Temperature Sensor Resistance
    Internal Resistance Unit: kΩ
toc
    Read OWNER'S MANUAL before operating.
        EMISSION CONTROL INFORMATION
            1.
            2.
        PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (United States Mo
        Foreword
        General Information
            Before starting to perform an inspection service or carry out a 
                Battery Ground
                Edges of Parts
                Solvent
                Cleaning vehicle before disassembly
                Arrangement and Cleaning of Removed Parts
                Storage of Removed Parts
                Inspection
                Replacement Parts
                Assembly Order
                Tightening Sequence
                Tightening Torque
                Force
                Gasket, O-ring
                Liquid Gasket, Locking Agent
                Press
                Ball Bearing and Needle Bearing
                Oil Seal, Grease Seal
                Circlips, Cotter Pins
                Lubrication
                Direction of Engine Rotation
                Electrical Wires
            KAF400-A1 Left Side View
            KAF400-A1 Right Side View
            KAF400-B1 Left Side View
            KAF400-B1 Right Side View
            Prefixes for Units
            Units of Temperature:
        Periodic Maintenance
            The scheduled maintenance must be done in accordance with this c
            The following tables list the tightening torque for the major fa
            Inside Circlip Pliers:
            Fuel System
                Throttle Pedal Free Play Inspection
                Throttle Pedal Free Play Adjustment
                Idle Speed Inspection
                Idle Speed Adjustment
                Air Cleaner Element Cleaning
                Fuel Hoses And Connections Inspection
                Fuel Hoses Replacement
                Fuel Filter Replacement
                Fuel System Cleanliness Inspection
                Engine Top End
                    Valve Clearance Inspection
                    Valve Clearance Adjustment
                        Torque -
                    Spark Arrester Cleaning
                Converter System
                    Drive Belt Inspection
                    Drive Belt Deflection Inspection
                    Drive Belt Deflection Adjustment
                        Torque -
                    Converter Driven Pulley Shoe Inspection
                    Converter Air Cleaner Element Cleaning/Inspection
                    Converter Dust or Water Drain
                Engine Lubrication System
                    Engine Oil Change
                        Torque -
                    Oil Filter Replacement
                        Special Tool -
                        Special Tool -
                        Torque -
                Transmission
                    Transmission Oil Change
                        Torque -
                Wheels/Tires
                    Wheels Nuts Tightness Inspection
                        Torque -
                    Tire Wear Inspection
                Final Drive (KAF400-A/C models)
                    Front Final Gear Case Oil Change
                        Torque -
                        Torque -
                Brakes
                    Brake Fluid Level Inspection
                    Brake Fluid Change
                        Torque -
                        Torque -
                    Brake Pedal Play Inspection
                        Torque -
                    Brake Master Cylinder Cup and Dust Seal Replacement
                        Special Tool -
                        Torque -
                    Brake Hose and Pipe Inspection
                    Brake Hose and Pipe Replacement
                        Torque -
                        Torque -
                    Brake Wear Inspection
                    Brake Wheel Cylinder Assembly Replacement
                        Sealant -
                        Torque -
                    Parking Brake Lever Inspection
                Steering
                    Steering Inspection
                    Steering Joint Dust Boot Inspection
                Frame
                    Seat Belt Inspection
                        Torque -
                Electrical System
                    Spark Plug Cleaning/Inspection
                    Spark Plug Gap Inspection
                    Electrolyte Level Inspection
                    Electrolyte Specific Gravity Inspection
                    Brake Light Switch Inspection
                General Lubrication
                    Pivots and Points: Lubricate with Grease.
                    Cables: Lubricate with Rust Inhibitor.
                    Cables: Lubricate with Motor Oil.
                Bolts, Nuts, and Fasteners
                    Tightness Inspection
                        Nut, Bolt, and Fasteners to be checked
        Fuel System
            Throttle Pedal Free Play Inspection
                Throttle Pedal Free Play Adjustment
                Full Throttle Pedal Position Adjustment
                Throttle Cable Installation
                Throttle Cable Lubrication
                Throttle Cable Inspection
            Control Panel Assembly Removal
                Control Panel Assembly Installation
                    Torque -
                Governor Assembly Removal
                Governor Assembly Installation
                Governor Assembly Inspection
            Choke Knob Free Play Inspection
                Choke Knob Free Play Adjustment
                Choke Cable Installation
                Choke Cable Lubrication
                Choke Cable Inspection
            Idle Speed Inspection
                Idle Speed Adjustment
                Fuel System Cleanliness Inspection
                Carburetor Removal
                Carburetor Installation
                    Torque -
                Carburetor Disassembly
                Carburetor Assembly
                    Torque -
                Carburetor Cleaning
                Carburetor Inspection
                Pilot Screw Setting
            Air Cleaner Element Removal
                Air Cleaner Element Installation
                Air Cleaner Housing Removal
                Air Cleaner Housing Installation
                    Torque -
                Air Cleaner Housing Dust and/or Water Installation
            Fuel Pump Removal
                Fuel Pump Installation
                    Torque -
                Fuel Pump Inspection
            Fuel Filter Removal
                Fuel Filter Installation
                Fuel Filter Inspection
            Fuel Tank Removal
                Fuel Tank Installation
                Fuel Tank Cleaning/Inspection
        Engine Top End
            Compression Gauge, 20 kgf/cm :
            Cylinder Compression Measurement
                Special Tools -
                Cylinder Head Removal
                Cylinder Head Installation
                    Torque -
                    Torque -
                Push Rod Inspection
                Valve Mechanism Removal/Installation
                Rocker Arm Inspection
                Cylinder Head Warp
            Valve Clearance Inspection
                Valve Clearance Adjustment
                Valve Seat Inspection
                Valve Seat Repair
                    Special Tools -
                Valve Spring Free Length
                Valve Head Thickness
                Valve Stem Bend
                Valve Stem Diameter
                Valve Guide Inside Diameter
                Measuring Valve/Guide Clearance (Wobble Method)
            Exhaust Pipe Removal
                Muffler Removal
                Exhaust Pipe and Muffler Installation
                    Torque -
                Exhaust Pipe and Muffler Inspection
                Spark Arrester Cleaning
        Converter System
            Outside Circlip Pliers:
            Air Cleaner Element Removal
                Air Cleaner Element Cleaning/Inspection
                Air Cleaner Housing Removal
            Torque Converter Removal
                Special Tool -
                Torque -
                Special Tool -
                Special Tools -
                Special Tool -
                Torque Converter Installation
                    Special Tools -
                    Torque -
                    Special Tool -
                    Torque -
                    Torque -
                Torque Converter Case Removal
                Torque Converter Case Installation
                    Torque -
            Drive Belt Removal
                Drive Belt Installation
                Drive Belt Inspection
                Drive Belt Deflection Inspection
                Drive Belt Deflection Adjustment
            Drive Pulley Removal
                Drive Pulley Disassembly
                    Special Tool -
                    Special Tool -
                Drive Pulley Inspection
                Spider Shoe Side Clearance Adjustment
                    Special Tool -
                Bushing Installation
                    Special Tool -
                    Special Tool -
                Drive Pulley Assembly
                    Torque -
                    Special Tool -
                    Special Tool -
                    Torque -
                    Torque -
                Drive Pulley Installation
            Driven Pulley Removal
                Driven Pulley Disassembly
                    Special Tool -
                    Special Tool -
                Driven Pulley Inspection
                Converter Driven Pulley Shoe Inspection
                Bushing Installation
                    Special Tool -
                Driven Pulley Assembly
                    Torque -
                    Special Tool -
                    Special Tool -
                    Special Tool -
                Driven Pulley Installation
        Engine Lubrication System
            WARNING
                Oil Level Inspection
                Engine Oil Change
                Oil Filter Replacement
            Oil Pump Removal
                Oil Pump Installation
                Oil Pump Inspection
                Relief Valve Removal
                Relief Valve Installation
                Relief Valve Inspection
            Oil Screen Removal
                Oil Screen Installation
                Oil Screen Cleaning/Inspection
            Oil Temperature Sensor Removal
                Oil Temperature Sensor Installation
                    Torque -
        Engine Removal/Installation
            Alignment Jig:
            Engine Removal
                Engine Installation
                    Special Tool -
                    Torque -
        Engine Bottom End
            Piston Ring Compressor Grip:
            Crankcase Cover Removal
                Crankcase Cover Assembly
                    Special Tool -
                Crankcase Cover Installation
                    Torque -
            Camshaft, Tappet Removal
                Camshaft, Tappet Installation
                    Torque -
                Camshaft Disassembly
                Camshaft Assembly
                Camshaft Inspection
                Camshaft Bearing/Journal Wear
            Piston Removal
                Piston Installation
                    Special Tools -
                    Torque -
                Piston Cleaning
                Piston Ring and Ring Groove Wear
                Piston Ring End Gap
                Piston Pin, Piston Pin Hole, and Connecting Rod Wear
                Piston Diameter
                Cylinder Inside Diameter
            Connecting Rod Removal
                Connecting Rod Installation
                Crankshaft Removal
                Crankshaft Installation
                Cleaning/Inspection 
                Connecting Rod Bend/Twist
                Connecting Rod Big End/Crankpin Width Wear
                Connecting Rod Big End Bearing/Crankpin Wear
                Crankshaft Runout
                Crankshaft Main Bearing/Journal Wear
            Balancer Shaft Removal
                Balancer Shaft Installation
                Balancer Shaft Bearing/Journal Wear
            The function of the breather is to create a negative pressure in
                Breather Valve Removal
                Breather Valve Installation
                    Torque -
                Breather Valve Inspection
        Transmission
            Outside Circlip Pliers:
            CAUTION
                Transmission Oil Level Inspection
                Transmission Oil Change
            Transmission Case Removal
                Transmission Case Installation 
                    Special Tool -
                    Torque -
                    Torque -
                Transmission Case Disassembly
                    Special Tool -
                    Special Tool -
                    Special Tool -
                Transmission Case Assembly
                    Torque -
                    Torque -
                    Special Tool -
                    Torque -
                    Special Tool -
                    Sealant -
                    Torque -
            Transmission Cable Installation
                Torque -
                Transmission Shift Cable Inspection
                Shift Rod Bending
                Shift Fork Ear and Shifter Groove Wear
                Transmission and Shift Mechanism Inspection
            2WD/4WD Shift Cable Adjustment
                2WD/4WD Shift Cable Lubrication
                2WD/4WD Shift Cable Inspection
                2WD/4WD Shift Mechanism Removal
                2WD/4WD Shift Mechanism Inspection
            Differential Shift Cable Adjustment
                Differential Shift Cable Lubrication
                Differential Shift Cable Inspection
                Differential Shift Mechanism Removal
                Differential Shift Mechanism Installation
                    Torque -
                    Torque -
                Differential Shift Mechanism Inspection
                Differential Gear Removal
                Differential Gear Installation
                    Torque -
                Differential Gear Inspection
            Bearing Replacement
                Special Tools -
                Special Tool -
                Ball Bearing Inspection
                Needle Bearing Inspection
                Oil Seal Inspection
        Wheels/Tires
            Jack:
            Toe-in is the amount that the front wheels are closer together i
                Toe-in Adjustment
                    Torque -
            Wheel Removal
                Special Tool -
                Wheel Installation
                    Torque -
                Wheel (Rim) Inspection
                Wheel (Rim) Replacement
            Tire Removal 
                Tire Installation 
                Tire Wear Inspection
        Final Drive
            Bearing Puller:
            Front Final Gear Case Oil Level Inspection 
                Torque -
                Front Final Gear Case Oil Change
                Front Final Gear Case Removal
                Front Final Gear Case Installation
                Front Final Gear Case Disassembly
                    Special Tool -
                    Special Tool -
                Front Final Gear Case Assembly
                    Torque -
                    Torque -
                    Special Tool -
                    Sealant -
                    Torque -
                    Special Tool -
                Differential Unit Disassembly
                Differential Unit Assembly
                    Torque -
                LSD Clutch Torque Inspection
                LSD Clutch Plate Inspection
                Pinion Gear Unit Disassembly
                    Special Tool -
                    Special Tool -
                Pinion Gear Unit Assembly
                    Torque -
                Front Final Bevel Gear Adjustment
                    Torque -
                    Special Tool -
                    Special Tool -
                Front Final Gear Case (Backlash-Related Parts)
                Correct Tooth Contact Pattern: No adjustment is required.
                Incorrect Tooth Contact Patterns (Example 1)
                Incorrect Tooth Contact Patterns (Example 2)
                    Bevel Gear Inspection
                    Differential Gear Inspection
                    Ball Bearing Inspection
                    Oil Seal Inspection
            Driven Bevel Gear Removal
                Driven Bevel Gear Installation
                    Torque -
                Driven Bevel Gear Disassembly
                    Special Tools -
                Driven Bevel Gear Assembly
                    Special Tools -
                    Torque -
                    Special Tool -
                    Special Tool -
                Drive Bevel Gear Removal
                    Special Tool -
                Drive Bevel Gear Installation
                    Special Tool -
                    Torque -
                Bevel Gear Adjustment 
                    Special Tool -
                    Special Tool -
                    Torque -
                Bevel Gear Case (Backlash-Related Parts)
                    Bevel Gear Inspection
                    Ball Bearing/Oil Seal Inspection
            Front Propeller Shaft Removal
                Front Propeller Shaft Installation
                Rear Propeller Shaft Removal
                Rear Propeller Shaft Installation
                    Torque -
                Propeller Shaft Inspection
            Front Axle Removal (KAF400-A/C)
                Front Axle Installation (KAF400-A/C)
                Front Axle Removal (KAF400-B)
                Front Axle Installation (KAF400-B)
                    Torque -
                Rear Axle Removal
                Rear Axle Installation
                Axle Inspection
                Dust Boot Inspection (KAF400-A/C)
                Front Axle Joint Boot Replacement (KAF400-A/C)
                    Special Tool -
                    Special Tool -
                Ball Bearing Inspection
                Grease Seal Inspection
        Brakes
            Front Brake
            Rear Brake
            Clutch Spring Compressor:
            Brake Fluid Recommendation
                Brake Fluid Level Inspection 
                Brake Fluid Change
                Brake Line Air Bleeding 
                    Torque -
                    Torque -
            Brake Pedal Play Inspection
                Master Cylinder Removal
                Master Cylinder Installation
                    Torque -
                Master Cylinder Disassembly/Assembly
                Master Cylinder Inspection 
            Brake Hose and Pipe Inspection
                Brake Hose and Pipe Replacement
            Brake Drum Removal
                Special Tool -
                Special Tools -
                Brake Drum Installation
                    Special Tool -
                    Special Tool -
                    Torque -
                    Torque -
                Brake Drum Wear
            Brake Panel Assy Removal
                Brake Panel Assy Installation
                    Sealant -
                    Sealant -
                    Bond -
                    Torque -
                Brake Panel Disassembly
                Brake Panel Assembly
                    Torque -
                Wheel Cylinder Removal/Installation
                Wheel Cylinder Assembly
                Wheel Cylinder Inspection
                Brake Shoe Lining Wear
                Brake Shoe Spring Inspection
                Grease Seal Replacement
                    Special Tool -
                    Special Tool -
                    Special Tool -
                    Torque -
            Parking Brake Lever Travel Adjustment 
                Parking Brake Cable Lubrication/Inspection
        Suspension
            Outside Circlip Pliers:
            Strut (Front Shock Absorber) Removal
                Strut (Front Shock Absorber) Installation
                    Torque -
                Rear Shock Absorber Preload Adjustment
                    Special Tool -
                Rear Shock Absorber Removal
                Rear Shock Absorber Installation
                    Torque -
                Rear Shock Absorber Inspection
            Front Suspension Arm Removal
                Front Suspension Arm Installation
                    Torque -
                Front Suspension Arm Inspection
            Swingarm Removal
                Swingarm Installation
                    Torque -
                Swingarm Inspection
                Swingarm Joint Replacement
                    Special Tool -
                    Special Tool -
        Steering
            Inside Circlip Pliers:
            Steering Wheel Free Play Inspection
                Steering Wheel Centering
                    Torque -
                Steering Wheel and Steering Shaft Removal
                Steering Wheel and Steering Shaft Installation
                    Torque -
            Steering Gear Assembly Removal
                Steering Gear Assembly Installation
                    Torque -
                Steering Gear Preload Adjustment
                    Torque -
                Tie-rod Length Adjustment
                Dust Boot Inspection
            Steering Knuckle Removal
                Steering Knuckle Installation
                    Torque -
                Knuckle Bearing Removal
                    Special Tool -
                    Special Tool -
                Knuckle Bearing Installation
                    Special Tool -
                    Special Tool -
                Knuckle Joint Removal
                    Special Tool -
                    Special Tool -
                Knuckle Joint Installation
                    Special Tool -
                    Special Tool -
        Frame
            Seat Removal
                Seat Installation
                Seat Belt Removal
                Seat Belt Installation
                    Torque -
            Control Panel Removal
                Glove Compartment Removal
            Front Cargo Hood Removal
                Front Cargo Compartment Removal
                Front Cargo Compartment Installation
            Cargo Bed Removal
                Cargo Bed Assembly
                Cargo Bed Installation
                Cargo Bed Latch Position Inspection
                Cargo Bed Latch Position Adjustment
            Front Bar Removal
                Front Bar Installation
                    Torque -
                Rear Bar Removal
                Rear Bar Installation
                    Torque -
            Front Fender Installation
            Front Guard Removal
                Front Guard Installation
                Floor Center Panel Removal
                Floor Center Panel Installation
                Front Final Gear Case Guard Removal
                Front Final Gear Case Guard Installation
                Bottom Guard Removal
                Bottom Guard Installation
                Transmission Case Guard Removal
                Transmission Case Guard Installation
                Center Cover Removal
                Center Cover Installation
                Side Covers Removal
                Side Covers Installation
                Guard Plate Removal
                Guard Plate Installation
        Electrical System
            Spark Plug Wrench, Hex 21:
            Oil Temperature Warning Indicator Light [A]
            There are a number of important precautions that are musts when 
            Wiring Inspection
            Battery Removal
                Battery Installation
                Electrolyte Level Inspection
                Electrolyte Specific Gravity Inspection
                Charging Condition Inspection
                Initial Charging
                Ordinary Charging
                Battery Charging Rate/Time Table
                    Battery Test Charging
                        Special Tool -
            Alternator Rotor and Stator Removal
                Alternator Rotor and Stator Installation
                    Torque -
                    Torque -
                    Torque -
                Charging System Operational Inspection
                Stator Coil Resistance
                Regulator/Rectifier Inspection
                Charging System Circuit
            WARNING
                Spark Plug Removal
                    Special Tool -
                Spark Plug Installation
                    Torque -
                Spark Plug Cleaning/Inspection
                Spark Plug Gap Inspection
                Ignition Coil Removal
                Ignition Coil Installation
                    Torque -
                Ignition Coil inspection
                    Special Tool -
                Ignition System Circuit
            Starter Motor Removal
                Starter Motor Installation
                    Torque -
                Starter Solenoid Inspection
                Starter Motor Inspection
                Starter Motor Disassembly
                Starter Motor Assembly
                Starter Motor Brush Inspection
                Brush Spring Inspection
                Armature Inspection
                Yoke Assembly Inspection
                Pinion Clutch Inspection
                Starter Circuit Relay Inspection
                Electric Starter Circuit
            Headlight Beam Adjustment
                Headlight Bulb Replacement
                Tail/Brake Light Replacement
                Light Switch Bulb Replacement
                Indicator Light Bulb Replacement
                Lighting System Circuit
            Brake Light Switch Inspection
                Oil Temperature Sensor Inspection (KAF400-A/C)
                Oil Temperature Warning Indicator Control Unit Inspection (KAF40
                    Special Tool -
                Oil Temperature Warning Control System Circuit
                    Switch Inspection
                    Neutral Switch Connections
                    Reverse Light Switch Connections (Europe Model)
                    Horn Switch Connections (Europe Model)
            Fuse Removal
                Fuse Installation
                Fuse Inspection
        Appendix
            NOTE
                Engine Doesn't Start, Starting Difficulty:
                    Starter motor not rotating:
                    Starter motor rotating but engine doesn't turn over:
                    Engine won't turn over:
                    No fuel flow:
                    Engine flooded:
                    No spark; spark weak:
                    Compression Low:
                Poor Running at Low Speed:
                    Spark weak:
                    Fuel/air mixture incorrect:
                    Compression low:
                    Other:
                Poor Running or No Power at High Speed:
                    Firing incorrect:
                    Fuel/air mixture incorrect:
                    Compression low:
                    Knocking:
                    Miscellaneous:
                Overheating:
                    Firing incorrect:
                    Fuel/air mixture incorrect:
                    Compression high:
                    Engine load faulty:
                    Converter and/or belt excessive heating:
                    Lubrication inadequate:
                    Front final gear case overheating (KAF400-A/C):
                    Cooling system component incorrect:
                Converter Operation Faulty:
                    Belt slipping:
                    Converter engagement speed too low:
                    Converter engagement speed too high:
                    Shifting too quickly:
                    Shifting too slowly:
                Gear Shifting Faulty:
                    Doesn't go into gear:
                    Jumps out of gear:
                    Overshifts:
                Abnormal Engine Noise:
                    Knocking:
                    Piston slap:
                    Valve noise:
                    Other noise:
                Abnormal Drive Train Noise:
                    Converter noise:
                    Transmission noise:
                    Final drive noise:
                Abnormal Frame Noise:
                    Shock absorber noise:
                    Brake noise:
                    Other noise:
                Exhaust Smokes Excessively:
                    White smoke:
                    Black smoke:
                    Brown smoke:
                Handling and/or Stability Unsatisfactory:
                    Steering wheel hard to turn:
                    Noise when turning (KAF400-A/C):
                    Steering wheel shakes or excessively vibrates:
                    Steering wheel pulls to one side:
                    Shock absorption unsatisfactory:
                Brake Doesn't Hold
                Battery Discharged:
                Battery Overcharged:
                
                -