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kawasaki mule 610 manual: Engine Removal and Installation

kawasaki mule 610  Engine Removal

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•Disconnect:
Battery Terminal Leads (see Electrical System chapter)

•Remove:
Cargo Bed
Guard Plate (see Frame chapter)
Exhaust Pipe (see Engine Top End chapter)
Torque Converter Case (see Converter System chapter)
Connecting Plate (see Transmission Case in the Trans-mission chapter)
Carburetor (see Fuel System chapter)
Link Bracket [A]
Starter Motor Lead [B] and Connector [C]
Alternator Lead Connector [D]
Ignition Coil Lead Connector [E]
Oil Temperature Sensor Lead Connector [F]
Hose [G]
•Remove:
Engine Mounting Bolts [A] (both sides)
Engine Ground Lead [B]
•Remove:
Engine [A]

kawasaki mule 610 Engine Installation

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If the transmission case has not been removed, start from the step 2.
Step 1
•Mount the transmission case [A] with the rear axle brack-ets [B] on the swingarm.
•Tighten the rear axle bracket bolts [C] lightly by hand.
Step 2
•Mount the engine [D] on the swingarm.
•Install the engine mount bolts and tighten the nuts [E]
lightly by hand.
•Install the connecting plate [F] to the engine and trans-mission case so that the plate fits to the face shown by spigot joint areas [G].
•Apply a non-permanent locking agent:
Connecting Plate Bolts (M10) [H]
Connecting Plate Bolts (M8) [I]
•Install the washers and tighten the connecting plate bolts(M10 and M8) lightly by hand.
•Install the alignment jig [J] and tighten the bolts.

Special Tool – Alignment Jig: 57001-1631

•Tighten the bolts in the following order.
Torque – Connecting Plate Bolts (M10): 55 N·m (5.6 kgf·m,41 ft·lb)
Connecting Plate Bolts (M8): 28 N·m (2.9 kgf·m,21 ft·lb)
Engine Mounting Bolts and Nuts: 24.5 N·m (2.5kgf·m, 18 ft·lb)
Rear Axle Bracket Bolts: 34 N·m (3.5 kgf·m, 25ft·lb)
•Remove the alignment jig.

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