replacing stator coils on mule 610

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Kawasaki Mule Roof 600, 610 and 4010 Trans Crew, Roof Installation Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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INSTALLTION INSTRUCTIONS – Mule 600/610 (4010 Trans skip to pg 4) 1. Place Roof Panel on top of UTV Roll cage and center front to back, and left to right. 2. Using Figure 1 Below – place UTV Roof Mounting Brackets around roll cage bar and using a marker, mark the position of the holes needed in the roof for each Roof Mounting bracket . Figure 1 Copyright 2007 DiamondBack Automotive Accessories, Inc. Page 3 3. Next, remove the roof from the roll cage and using a drill with 1/4″ bit, drill holes using the marks as a guide. 4. Cut (4) 3″ strips of adhesive foam and apply to roof in where mounting brackets are positioned to prevent roof rattling once mounted. Foam should run in the direction of the roll cage as shown in Figure 1 above. 5. Next, reposition the roof on the roll cage according to step 1. 6. Prior to attaching the roof mount brackets, cut the remaining adhesive foam in half and apply one section to the roof in the center of the roof where roof and each roll cage bar meet as shown in Figures 1 above. If additional tape is required to prevent rattling it can be purchased from any hardware store as window sealant foam tape. 7. Next, attach the roof mount brackets according to Figure 2. Use channel locks or pliers to hold top of carriage bolt and turn nut with 7/16″ socket.

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Kawasaki MULE 600 / 610 SNOW PLOW INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. PRELIMINARY: 1.1 Remove the six 6 mm. screws and plastic skid / splash shield from the bottom front of the vehicle frame. (These bolts and plastic skid / splash shield will not be reused snow plow mounting frame installed onto the vehicle.) 1.2 If the vehicle has the Kawasaki optional brush guard installed, it will have to be removed and then reinstalled after the snow plow mounting frame is installed. (The brush guard will fit with the snow plow mounting frame installed first.) 2. VEHICLE MOUNTING FRAME 2.1 Position the vehicle mounting frame (13) under the front of the vehicle so that the six holes (with pipe spacers) line up with the six 6 mm. threaded holes that the plastic skid / splash shield was attached with and the upper plate is through the large oval hole in the vehicle plastic fascia. Fasten loosely using 6mm. x 1.0mm. x 30mm. bolts (33) , 6mm. lock washers (35) and 6mm. flat washers (34). 2.2 Place a 5/16″-18 “U” bolt (36) around the front cross tube behind the plastic fascia and through each set of holes in the flange of the upper plate of the vehicle mounting frame (total of two “U” bolts). Fasten loosely using 5/16″flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.3 Install a 5/16″-18 “U” bolt (36) around the lower frame tubes and through each set of slotted holes in the lower plate of the vehicle mounting frame (total of four “U” bolts). Fasten loosely using 5/16″ flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.4 Tighten all the fasteners holding the vehicle mounting frame to the vehicle starting with the 6mm. bolts

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Kawasaki Mule 610 Windshield Installation And Operations Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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Seizmik Hybrid Roof Frame Kit Contents: A. Windshield Mount Top Brackets and Hardware (2) B. Windshield Clamps and Hardware (2) (not shown) C. Windshield (1) (not shown) A B C D E F G H I J K L M Note: All hardware and brackets may not be shown in this view. Windshield Top Mount Hardware Includes: A. M6x22mm Socket Head Bolts (4) B. M6x12mm Socket Head Bolts (4) C. M8 Standard Flat Washers (4) D. Compression Sleve (2) E. M8x18mm Socket Head Bolt (2) F. Windshield Stay Assembly (2) G. 1.875″ Bar Clamp Half (4) H. Windshield bracket (2) I. Windshield clamp plate (2) J. Windshield clamp gasket (4) K. M6x25mm hex head bolt (4) L. M6 flat washer (8) M. M6 hex lock nut (4) Windsheild Lower Clamp Hardware (not shown) Includes: A. M6 x 40mm Zinc Coated Hex Head Bolt (2) B. M6 Standard Flat Washer (4) C. M6 Zinc Coated Nut (2) D. M6 Wide Flange Nut (2) E. 2″ Tube Clamp (2) F. 2″ Rubber Grip Strip (2) 3 Installation Instructions: Use the passenger side clamp to ensure proper positioning. The clamp should be positioned as shown. The driver’s side clamp should be even with the passenger’s side

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Kawasaki Mule 610 Without coil springs Installation

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Filed Under (Kawasaki) by admin on 25-10-2010

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1.)Begin by loosening the lug nuts on both front tires. Raise the unit, using a suitable lifting device or procedure, until the front tires are off the ground. If using a floor jack with stands, chock the rear wheels to prevent the unit from rolling. If using jack stands, make sure the stands are placed under the frame and not the body. Make sure the unit is stable and secure . 2.)Remove the tires / wheels. NOTE: Now is a good time to check the threads on the lug studs. Check for rust, pulled threads or other deterioration that could cause a stud/thread failure. 3.) The first thing to do is remove the front cowl and trunk on the bike. You can accomplish this by removing all the bolts (screws) around the perimeter of the cowl and removing some plastic “snap rivets”. To remove the rivets simply pull the center section up and then the rest will follow. 4.)Place a floor jack, or other suitable device, beneath the left side lower control arm. This is to prevent damage to the tie rod or slip yoke boot while disassembling the lower control arm and strut. Using a 14mm socket, remove the two retaining nuts and lock washers on the top of the struts. 5.)Leaning the strut forward toward the headlamp buckets will put the strut in position to allow you to reach over the top and place the strut spacer in place. Install the strut spacer on top of the coil retainer and tightening the nuts. Install the supplied gasket on top of the strut spacer, and re-install the strut assembly

2005-2007 Kawasaki 610 Mule Winch Mount Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Remove the plastic lower front cover. 2. Remove the two bolts on the left side mud shield that connect to the frame for easier access. 3. Install the winch to the winch mount using the hardware supplied with the winch. 4. Install the winch and mount per the illustration using the provided U-Bolts, flat washers and nuts around the frame tubes and through the mount. Tighten all nuts and bolts securely. 5. Install the roller fairlead to the winch mount using (2) 5/16″ x 3/4″ bolts and 5/16″ nylock nuts provided. (Rollers should turn freely. NOTE: Bottom roller may need to be removed to run wire rope through. 6. Using the instructions provided with the winch, wire accordingly. 7. Reinstall the two bolts from the mud shield. 8. Reinstall the plastic lower front cover. NOTE: For some winches, this cover may need to be trimmed so it does not rub

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Kawasaki Mule Lift Kit Installation Manual

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Filed Under (Kawasaki) by admin on 04-05-2012

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Front Lift Installation 1. Ensuring that the parking brake is set, place jack under center of the Mule front end and lift until front wheels clear the ground. Be careful to support Mule properly so that it is secure, but so that the A-arms and struts can droop to full extension. 2. Remove front wheels. 3. If applicable, remove the heater to allow access to the strut mount behind the heater coil. Heater 4. Starting with the left side (driver side), remove the cotter pin and castle nut that secures the strut to the strut mount. Castle Nut & Pen 5. Push bolt through the bolthole, taking care not to damage the brake line that is attached to the bolt. If you are having difficulty removing the bolt, you may have to remove the brake lines that are attached to the front brakes. In this case refer to owners manual for removing brake lines. Screwdriver NOTE: Keep in mind that if you remove the brake lines you must bleed your brakes according to operator’s manual. 6. Once the bottom of the strut has been loosened, then unbolt the top of the strut. The nuts securing the top strut can be located in the dash of the Mule on the left and right sides. In most cases these nuts are easily accessible, but you may have to remove the glove box or heater coils, depending on the model and options purchased with the Mule.

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DYNA IGNITION COIL INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 08-11-2011

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Remove the gas tank. Locate the two ignition coils. 2) Unplug the primary wires coming from the coils and disconnect the high voltage wires from the spark plugs. Remove the coil mounting bolts, and remove the coils. 3) Cut or unsolder primary wires from coils. Crimp or solder ring terminals supplied with kit to primary wires.4) Attach the primary wires to the DYNA COILS using the 10-32 x 5/16 pan head screws provided. Either wire can be mounted on either terminal of the dual output coils as they have no polarity. On the single output coils, the primary terminal opposite the side with the output tower has a + marking. Plus 12 volts from the ignition switch is applied to that terminal, and the points or ignition system output is connected to the other terminal. On a Kawasaki, make sure there is clearance between the screw head and the mounting screw spacer. Do not over- tighten screws as damage to the coil could result. 5) Using the stock hardware, mount the coils to the frame in the original location. NOTE: The DYNA COIL mounting hole spacing is designed to accommodate early model Honda, Kawasaki, and Suzuki motorcycles. There are a wide variety of physical sizes and mounting configurations on the late model motorcycles and it may e necessary to modify existing mounting brackets, or fabricate a bracket to adapt the DYNA COILS to your particular motorcycle

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Kawasaki KX 80 1992-ON, KX100 IGNITION STATOR Installation instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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Take the ignition cover off. Take note of the wire colors of the original stator wires and disconnect them from the wiring loom. Remove the flywheel using a proper puller tool. Remove the baseplate with the original stator. Remove the screws that secure the coil and take the coil off. Cut the original wires close to the original coil. Take a good look at how the wires are connected to the coil. (at which side of the original coil which wire color goes). Connections: Connect the wire colors accord- ing to the drawing. RED and BLACK/RED Connect the old wires up to the new coil. Put the wires in exactly the same place as on the original. Make sure you have good connections here. Use a soldering iron and rosin core solder (the type used in electrical applications). Mount the coil onto the baseplate, fit the screws using locking compound on the threads and TIGHTEN THE SCREWS SECURELY! Refit the stator baseplate. Ensure the wires CANNOT TOUCH THE FLYWHEEL! (especially on the inside of the flywheel) Refit the flywheel. Tighten the bolt to specified torque

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Pulsar XR 650R ELECTRIC-START KIT INSTALLATION INSTRUCTIONS

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Remove the seat, fuel tank, side panels, muffler, and headers. 2. Disconnect the stator wires from their corresponding mates underneath the seat (trace the wires up from the left side case.) Un-route the stator wiring so it hangs free from the left side case. 3. Remove the stock shift lever and the left side engine case cover. You do not need to drain the oil from the engine. 4. Unbolt and remove the stator and wiring from the stock cover. Do not cut any wires. 5. The stock pulsar coil (small black box hanging from the stator) will have to be modified slightly to clear the ring gear before installation into the new cover. Remove (file or grind) about .030 inches of material from the base of the pulsar coil so that the base is flush with the face of the rest of the coil as shown in Photos 1 and 2. File Here Photo 2 Make flush with this surface Remove material here Photo 1 6. Install the stator and modified pulsar coil into the new engine case cover as shown in Photo 3. Use the three provided Phillips head bolts, split lock-washers, and plastic cable clamps to secure the wiring as shown. You will need to pull about ½” of extra wire through the grommet (Photo 4) to give you enough wire length for the grommet to sit in its case cutout. To do this, remove the electrical tape from the end of the stator wires and pull each wire individually through the grommet. Neither of the stock metal wire guides will be used when reinstalling the stator into the new case (Photo 5). 5/16″ cable clamps 1/8″ cable clamp Photo 3 Photo 5 Not Used Pull extra wire through grommet Photo 4 7. Remove the stock flywheel nut (An air impact tool works best to remove this nut without turning the motor). Remove the flywheel using the flywheel puller provided. 8. Locate the T and F marks on the stock flywheel (Photo 6). The T mark is used to adjust valve clearances and its location needs to be transferred to the ring gear. Scribe a line in the edge of the flywheel in line with the T mark as shown in Photo 7

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HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

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