Owners Manual
Page 5
... blow-by fuel evaporation in the fuel system are led to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of a catalytic converter in the muffler (California model only), a modified carburetor and ignition system having optimum ignition timing characteristics. Also, vapors caused by gases are not vented into the running engine to the bottom of vehicles operated at high altitude, Kawasaki recommends the...
... blow-by fuel evaporation in the fuel system are led to provide lean air/fuel mixture characteristics and optimum fuel economy with applicable regulations of a catalytic converter in the muffler (California model only), a modified carburetor and ignition system having optimum ignition timing characteristics. Also, vapors caused by gases are not vented into the running engine to the bottom of vehicles operated at high altitude, Kawasaki recommends the...
Owners Manual
Page 6
... parts: Carburetor and internal parts Spark plug Magneto or electronic battery ignition system Fuel filter Air cleaner element the acts listed below: NOTE hoses • Fuel Fuel tank • Muffler and carbon canister (California model only) • To assist you have the responsibility to have provided space at your vehicle. Tampering with the applicable standards. As the owner of certain carburetor components and belt drive torque converter components.
... parts: Carburetor and internal parts Spark plug Magneto or electronic battery ignition system Fuel filter Air cleaner element the acts listed below: NOTE hoses • Fuel Fuel tank • Muffler and carbon canister (California model only) • To assist you have the responsibility to have provided space at your vehicle. Tampering with the applicable standards. As the owner of certain carburetor components and belt drive torque converter components.
Owners Manual
Page 8
... of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. KAWASAKI HEAVY INDUSTRIES, LTD. It is sold. The Service Manual contains detailed disassembly and maintenance information. This publication includes the latest information available at all times so that you need information. FOREWORD Congratulations on their own work should remain with the proper operation of your vehicle's controls, its features...
... of Kawasaki's engineering expertise and a tradition of manufacturing high-quality consumer products. KAWASAKI HEAVY INDUSTRIES, LTD. It is sold. The Service Manual contains detailed disassembly and maintenance information. This publication includes the latest information available at all times so that you need information. FOREWORD Congratulations on their own work should remain with the proper operation of your vehicle's controls, its features...
Owners Manual
Page 9
... ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (KAF400 A/C) ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A/C)...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
... ...SPECIFICATIONS ...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS ...LOADING INFORMATION ...GENERAL INFORMATION ...Lighting/Electrical Accessory Connector ...Brake Pedal...Cargo Bed ...Choke Knob...Engine Oil Temperature Warning Light (KAF400 A/C) ...Fuel Tank...Fuel Gauge...Glove Compartment ...Front Cargo Compartment ...Ignition Switch ...Hour Meter ...Light Switch ...Shift Levers ...Gear Shift Lever ...2WD-4WD Shift Lever (KAF400A/C)...Differential Shift Lever ...Parking Brake Lever...Parking Brake Warning Light...Seat ...Seat Belts ...Throttle Pedal ...Trailer Hitch...
Owners Manual
Page 10
Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System (California model only) ...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ......
Valve Clearance ...Engine Air Cleaner ...Spark Arrester ...Throttle Pedal ...Choke Knob...Carburetor ...Fuel System ...Fuel Filter ...Evaporative Emission Control System (California model only) ...Belt Drive Torque Converter ...Belt Drive Torque Converter Air Cleaner ...Brakes ...Brake Pedal...Brake Light Switch...Parking Brake Lever...Steering Wheel...Wheels ...Rims ...Wheel Nuts...Tires ...Joint Boots...Suspension...Seat Belts ...Headlight Beam ...Battery ...Fuse ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ......
Owners Manual
Page 13
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C) 29.7 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) (B) 27.9 N·m (2.8 kgf·m, 21.0 ft·lb) @2 ...lb) (C) 469 kg (1 034 lb) 1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in)
SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Track: Front Rear Ground Clearance Curb Mass Curb Mass (California model only) Cargo Bed (L × W × H) ENGINE Type Displacement (A/C) 29.7 N·m (3.0 kgf·m, 22.0 ft·lb) @2 400 r/min (rpm) (B) 27.9 N·m (2.8 kgf·m, 21.0 ft·lb) @2 ...lb) (C) 469 kg (1 034 lb) 1 044 × 900 × 245 mm (41.10 × 35.43 × 9.65 in.) OHV, 1-cylinder, 4-stroke, positive air-cooled 401 cm³ (24.47 cu in)
Owners Manual
Page 14
...; Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse 9.263 (High) (A/C) 13.706 (Low) 11.910 (A/C) 3.851 4.000 (A/C) Gear (2WD/4WD) (B) Gear (2WD) (A/C) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) 82 × 76 mm (3,23 × 2.99 in.) (A/C) 8.6 : 1 (B) 8.3 : 1 Electric starter NIKKI 6C1026 Magneto...
...; Stroke Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Lubrication System Engine Oil Engine Oil Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Front Rear Overall Drive Ratio: Forward Reverse 9.263 (High) (A/C) 13.706 (Low) 11.910 (A/C) 3.851 4.000 (A/C) Gear (2WD/4WD) (B) Gear (2WD) (A/C) 2-speed & reverse, automatic (B) 1-speed & reverse, automatic 3.653 ∼ 0.794 (Belt drive torque converter) 82 × 76 mm (3,23 × 2.99 in.) (A/C) 8.6 : 1 (B) 8.3 : 1 Electric starter NIKKI 6C1026 Magneto...
Owners Manual
Page 20
Parking Brake Warning Light 33. 34. 35. 36. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Accessory Connector 39. 40. 41. 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Ignition Switch 38. 18 LOCATION OF PARTS 28. 29. 30. 31. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch
Parking Brake Warning Light 33. 34. 35. 36. Hour Meter Gear Shift Lever Front Cargo Latch 2WD-4WD Shift Lever (KAF400A/C) 37. Accessory Connector 39. 40. 41. 42. Differential Shift Lever Choke Knob Horn Button Engine Oil Temperature Warning Light 32. Ignition Switch 38. 18 LOCATION OF PARTS 28. 29. 30. 31. Glove Compartment Brake Fluid Level Brake Light Switch Light Switch
Owners Manual
Page 29
...; cially designed for your weight. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use on top of the cab frame. In selecting and using accessories, and in loading the vehicle, you must take care in an unpredictable manner. NOTICE The front body work and fenders are personally responsible for use of accessories, or modification of your...
...; cially designed for your weight. LOADING INFORMATION 27 LOADING INFORMATION WARNING Incorrect loading, improper installation or use on top of the cab frame. In selecting and using accessories, and in loading the vehicle, you must take care in an unpredictable manner. NOTICE The front body work and fenders are personally responsible for use of accessories, or modification of your...
Owners Manual
Page 42
... turn the ignition switch key to the "START" position with a starter lockout switch. Write your key number here. żThe NOTE vehicle is in the event that your original keys are available at your keys. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is equipped with the engine running, or damage to recover power. NOTICE Do not operate the starter continuously for the battery...
... turn the ignition switch key to the "START" position with a starter lockout switch. Write your key number here. żThe NOTE vehicle is in the event that your original keys are available at your keys. Electric starter is engaged by holding ignition switch key in this position, only when gear shift lever is equipped with the engine running, or damage to recover power. NOTICE Do not operate the starter continuously for the battery...
Owners Manual
Page 53
.... Check for cuts, cracks, damage, or excessive wear. The time required is cold), no leaks. j WARNING Failure to perform these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. Tires ...Air pressure (when cold): KAF400A/C Front Rear 47 kPa (0.47 kgf/cm², 7 psi) 97...
.... Check for cuts, cracks, damage, or excessive wear. The time required is cold), no leaks. j WARNING Failure to perform these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. Tires ...Air pressure (when cold): KAF400A/C Front Rear 47 kPa (0.47 kgf/cm², 7 psi) 97...
Owners Manual
Page 54
Brake fluid level between level lines, no leaks. Battery ...Electrolyte level between level lines in .). Throttle pedal operates smoothly and returns to lights. Steering ...Steering wheel free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Parking brake lever travel: 8 ∼ 12 clicks. Electrical Equipment ...All lights and horn work. j 52 HOW TO OPERATE Transmission Case Oil ...Oil level between H and L lines, no leaks. Brake pedal free play 0 ∼ 20 mm (0 ∼ 0.8 in .). Action smooth...
Brake fluid level between level lines, no leaks. Battery ...Electrolyte level between level lines in .). Throttle pedal operates smoothly and returns to lights. Steering ...Steering wheel free play 2 ∼ 5 mm (0.1 ∼ 0.2 in .). Parking brake lever travel: 8 ∼ 12 clicks. Electrical Equipment ...All lights and horn work. j 52 HOW TO OPERATE Transmission Case Oil ...Oil level between H and L lines, no leaks. Brake pedal free play 0 ∼ 20 mm (0 ∼ 0.8 in .). Action smooth...
Owners Manual
Page 55
..., odorless poisonous gas. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the switch. • j Mechanism of the choke knob.) żWhen engine is cold and air temperature is equipped with the following procedure. Push down the throttle pedal slightly. Inhaling carbon monoxide can feel this choke system, start po• Turn sition to...
..., odorless poisonous gas. the parking brake. • Apply Put the shift lever in the "N" (Neutral) position. • Put the gear ignition key in the switch. • j Mechanism of the choke knob.) żWhen engine is cold and air temperature is equipped with the following procedure. Push down the throttle pedal slightly. Inhaling carbon monoxide can feel this choke system, start po• Turn sition to...
Owners Manual
Page 73
... use of use 4 years (D) ż Fuel hose-replace Evaporative emission control system-function (California model only)* j • • D • • D CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect D • •...
... use of use 4 years (D) ż Fuel hose-replace Evaporative emission control system-function (California model only)* j • • D • • D CHASSIS Steering-inspect Steering and axle shaft joint dust boots-inspect Brake pedal play-inspect* Parking brake lever-inspect Brake hose and pipe-inspect Brake fluid level-inspect Brake wear-inspect* Tire wear-inspect* Brake light switch-inspect Seat belt-inspect General lubrication-perform* Bolts, nuts, and fasteners tightness-inspect Wheel nuts tightness-inspect D • •...
Owners Manual
Page 84
... MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. Transmission case oil is damaged, replace it to the "H" (High) line on the dipstick with a new one. When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on tires can make them with its gasket...
... MAINTENANCE AND ADJUSTMENT WARNING The exhaust system can cause an accident and injury. Transmission case oil is damaged, replace it to the "H" (High) line on the dipstick with a new one. When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Clean off any oil that inadvertently gets on tires can make them with its gasket...
Owners Manual
Page 90
.... DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in accordance with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from the muffler. Clean the spark arrester in the "N" and lower engine speed while...
.... DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Drain Plug the parking brake. • Apply In an open area away from combustible materials, • start the engine with the gear shift lever in accordance with a rubber mallet until carbon particles are purged from the muffler. (Neutral) position. • Remove the drain plug from the muffler. Clean the spark arrester in the "N" and lower engine speed while...
Owners Manual
Page 95
... the idle speed is changed. Guard Plate B. Quick Rivets (6 p.c.s.) E. Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick rivets. A. Tighten the nuts after adjustment. Clamps (6 p.c.s.) D. MAINTENANCE AND ADJUSTMENT 93 Carburetor The idle speed adjustment should be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter...
... the idle speed is changed. Guard Plate B. Quick Rivets (6 p.c.s.) E. Idle Speed Adjustment the parking brake. • Apply Raise the seat. • Remove the guard plate by releasing the two air • intake ducts and the 6 quick rivets. A. Tighten the nuts after adjustment. Clamps (6 p.c.s.) D. MAINTENANCE AND ADJUSTMENT 93 Carburetor The idle speed adjustment should be performed in .) j Adjustment and turn the choke cable mounting nuts • Loosen next to the starter...
Owners Manual
Page 107
.... NOTICE A. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is located above the brake Inspection the ignition switch to...
.... NOTICE A. Throttle Pedal adjust the brake light switch, move the switch • To forward or rearward, by turning the adjusting nut. To avoid damaging the electrical connections inside the switch, be inspected in .) it does not, check the bulb and, if necessary, • If adjust the brake light switch. MAINTENANCE AND ADJUSTMENT 105 Brake Light Switch When the brake pedal is located above the brake Inspection the ignition switch to...
Owners Manual
Page 108
In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. D. Lights later. C. B. A. j Inspection A. 106 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. Brake Light Switch Adjusting Nut Lights sooner. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. Parking Brake Lever the parking brake lever up and to the rear. • Pull After to 12 clicks of lever travel, the vehicle • should8 not roll while parked.
In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. D. Lights later. C. B. A. j Inspection A. 106 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. Brake Light Switch Adjusting Nut Lights sooner. If it does, adjust the parking brake lever. • Adjustment • Raise the seat. Parking Brake Lever the parking brake lever up and to the rear. • Pull After to 12 clicks of lever travel, the vehicle • should8 not roll while parked.
Owners Manual
Page 124
.... Dispose of flame or sparks; Contact your local authorities for Storage: Clean the entire vehicle thoroughly. WARNING j Motor oil is well ventilated and free from the fuel tank, and empty the • Empty carburetor by loosening the drain screw at the float bowl. NOTE WARNING Fuel stabilizers may be explosive under certain conditions. Turn the engine over several times with a pilot light. Turn the ignition switch "OFF".
.... Dispose of flame or sparks; Contact your local authorities for Storage: Clean the entire vehicle thoroughly. WARNING j Motor oil is well ventilated and free from the fuel tank, and empty the • Empty carburetor by loosening the drain screw at the float bowl. NOTE WARNING Fuel stabilizers may be explosive under certain conditions. Turn the engine over several times with a pilot light. Turn the ignition switch "OFF".