2009-2011 Carryall 295 / XRT 1550 - Mobilicab

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CONTENTS SECTION 4 – BRAKE SYSTEMS Front Brake Assembly .................................................................................................................................................................... 4-3 Rear Brake Assembly ...................................................................................................................................................................... 4-5 Master Cylinder with Remote Reservoir ................................................................................................................................. 4-7 Master Cylinder with Integral Reservoir ................................................................................................................................. 4-9 Hydraulic Brake Lines and Clips ................................................................................................................................................. 4-11 Brake Pedal Assembly ................................................................................................................................................................... 4-13 Park Brake System ........................................................................................................................................................................... 4-15 Park Brake Pedal Assembly .......................................................................................................................................................... 4-17 Front Brake Assembly (Style B) .................................................................................................................................................. 4-19 Rear Brake Assembly (Style B) .................................................................................................................................................... 4-21 SECTION 5 – STEERING AND SUSPENSION Steering Column ............................................................................................................................................................................. 5-3 Steering Gear Assembly ............................................................................................................................................................... 5-5 Front Suspension – A-Arms ......................................................................................................................................................... 5-7 Cv Boot Repair Kits ......................................................................................................................................................................... 5-9 Shock Absorbers – Standard ....................................................................................................................................................... 5-11 Shock Absorbers – High Capacity ............................................................................................................................................. 5-13 Rear Suspension – Standard ....................................................................................................................................................... 5-15 SECTION 6 – ELECTRICAL SYSTEM Wiring – Gasoline Vehicles, Single Piece ................................................................................................................................ 6-5 Wiring – Diesel Vehicle, Single Piece ....................................................................................................................................... 6-9 Electrical Component Box, Gasoline Vehicles ...................................................................................................................... 6-11 Electrical Component Box, Diesel Vehicles ........................................................................................................................... 6-13 Electrical Components – Gas ...................................................................................................................................................... 6-15 Electrical Components – Diesel ................................................................................................................................................. 6-17 Battery – Gasoline Vehicles ......................................................................................................................................................... 6-19 Battery – Diesel Vehicles .............................................................................................................................................................. 6-21 SECTION 7 – KAWASAKI FH680D GASOLINE ENGINE Shrouds and Brackets .................................................................................................................................................................... 7-3 Ignition Components and Flywheel ........................................................................................................................................ 7-5 Governor Arm and Springs .......................................................................................................................................................... 7-7 Oil and Lubrication Components .............................................................................................................................................. 7-9 Oil Filter Adapter ............................................................................................................................................................................. 7-11 Cylinder Head and Crankcase .................................................................................................................................................... 7-13 Page 2 2009-2011 Carryall 295 and XRT 1550 Gasoline and Diesel Vehicles Illustrated Parts List
CONTENTS Valves and Camshaft ..................................................................................................................................................................... 7-15 Pistons and Crankshaft ................................................................................................................................................................. 7-17 Kawasaki FH680D Gasoline Engine Mounting .................................................................................................................... 7-19 SECTION 8 – DIESEL ENGINE – CLOSED BREATHER Kubota D722 Diesel Engine Mounting ................................................................................................................................... 8-3 Crankcase .......................................................................................................................................................................................... 8-5 Oil Pan ................................................................................................................................................................................................ 8-7 Cylinder Head .................................................................................................................................................................................. 8-9 Gear Case ........................................................................................................................................................................................... 8-11 Head Cover ....................................................................................................................................................................................... 8-13 Dipstick and Guide ........................................................................................................................................................................ 8-15 Oil Pump ............................................................................................................................................................................................ 8-17 Main Bearing Case ......................................................................................................................................................................... 8-19 Camshaft and Idle Gear ................................................................................................................................................................ 8-21 Piston and Crankshaft ................................................................................................................................................................... 8-23 Flywheel ............................................................................................................................................................................................ 8-25 Shaft .................................................................................................................................................................................................... 8-27 Idle Apparatus ................................................................................................................................................................................. 8-29 Stop Solenoid .................................................................................................................................................................................. 8-31 60-Amp Alternator ......................................................................................................................................................................... 8-33 Injection Pump ................................................................................................................................................................................ 8-35 Speed Control Plate ....................................................................................................................................................................... 8-37 Nozzle Holders and Glow Plugs ................................................................................................................................................ 8-39 Governor Components ................................................................................................................................................................ 8-41 Starter ................................................................................................................................................................................................. 8-43 Valves and Rocker Arms ............................................................................................................................................................... 8-45 Diesel Inlet Manifold ..................................................................................................................................................................... 8-47 Exhaust Manifold ............................................................................................................................................................................ 8-49 Gasket Kits ......................................................................................................................................................................................... 8-51 Piston Kit ............................................................................................................................................................................................ 8-53 SECTION 9 – FUEL, INTAKE, & GOVERNOR SYSTEM Fuel System – Kawasaki Gasoline Vehicles ........................................................................................................................... 9-3 Fuel Tank – Gasoline Vehicles .................................................................................................................................................... 9-5 Fuel System – Diesel ...................................................................................................................................................................... 9-7 Fuel Tank – Diesel Vehicles ......................................................................................................................................................... 9-9 Carburetor Installation – Kawasaki Gasoline Vehicles ...................................................................................................... 9-11 Cables – Kawasaki Gasoline Vehicles ...................................................................................................................................... 9-13 2009-2011 Carryall 295 and XRT 1550 Gasoline and Diesel Vehicles Illustrated Parts List Page 3
Page 1: 2009-2011 All Wheel Drive Illustrat
Page 4 and 5: NOTE: This illustrated parts list r
Page 8 and 9: CONTENTS Cables - Diesel Vehicle ..
Page 11 and 12: BODY AND TRIM 1 G E D
Page 13 and 14: ITEM PART NO. DESCRIPTION 1 2 3 4 B
Page 15 and 16: ITEM PART NO. DESCRIPTION 1 2 3 4 F
Page 19 and 20: ITEM PART NO. DESCRIPTION 1 2 3 4 C
Page 21 and 22: ITEM PART NO. DESCRIPTION 1 2 3 4 C
Page 25 and 26: ITEM PART NO. DESCRIPTION 1 2 3 4 P
Page 27 and 28: ITEM PART NO. DESCRIPTION 1 2 3 4 S
Page 29 and 30: ITEM PART NO. DESCRIPTION 1 2 3 4 D
Page 31 and 32: ITEM PART NO. DESCRIPTION 1 2 3 4 G
Page 49 and 50: ITEM PART NO. DESCRIPTION 1 2 3 4 R
Page 51 and 52: ITEM PART NO. DESCRIPTION 1 2 3 4 L
Page 53 and 54: ITEM PART NO. DESCRIPTION 1 2 3 4 T
Page 55 and 56: ITEM PART NO. DESCRIPTION 1 2 3 4 E
Page 57 and 58:
ITEM PART NO. DESCRIPTION 1 2 3 4 B
Page 59 and 60:
ITEM PART NO. DESCRIPTION 1 2 3 4 S
Page 61 and 62:
ITEM PART NO. DESCRIPTION 1 2 3 4 C
Page 63 and 64:
WHEELS AND TIRES 2 G E D
Page 65 and 66:
ITEM PART NO. DESCRIPTION 1 2 3 4 W
Page 67 and 68:
DECALS 3 G E D
Page 69 and 70:
SAFETY DECALS - CA 295 AND XRT 1550
Page 71 and 72:
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
Page 79 and 80:
Page 81 and 82:
BRAKE SYSTEMS 4 G E D
Page 83 and 84:
ITEM PART NO. DESCRIPTION 1 2 3 4 F
Page 85 and 86:
ITEM PART NO. DESCRIPTION 1 2 3 4 R
Page 87 and 88:
ITEM PART NO. DESCRIPTION 1 2 3 4 M
Page 89 and 90:
ITEM PART NO. DESCRIPTION MASTER CY
Page 91 and 92:
ITEM PART NO. DESCRIPTION 1 2 3 4 H
Page 93 and 94:
Page 95 and 96:
ITEM PART NO. DESCRIPTION 1 2 3 4 P
Page 97 and 98:
Page 99 and 100:
Page 101 and 102:
Page 103 and 104:
STEERING AND SUSPENSION 5 G E D
Page 105 and 106:
Page 107 and 108:
Page 109 and 110:
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
Page 119 and 120:
ELECTRICAL SYSTEM 6 G E D
Page 121 and 122:
6 G E D 000662-001 2009-2011 Carrya
Page 123 and 124:
Page 125 and 126:
6 G E D 000662-002 2009-2011 Carrya
Page 127 and 128:
Page 129 and 130:
ELECTRICAL COMPONENT BOX, GASOLINE
Page 131 and 132:
ITEM PART NO. DESCRIPTION ELECTRICA
Page 133 and 134:
ITEM PART NO. DESCRIPTION 1 2 3 4 E
Page 135 and 136:
Page 137 and 138:
Page 139 and 140:
Page 141 and 142:
KAWASAKI FH680D GASOLINE ENGINE 7 G
Page 143 and 144:
Page 145 and 146:
ITEM PART NO. DESCRIPTION 1 2 3 4 I
Page 147 and 148:
ITEM PART NO. DESCRIPTION 1 2 3 4 G
Page 149 and 150:
ITEM PART NO. DESCRIPTION 1 2 3 4 O
Page 151 and 152:
Page 153 and 154:
Page 155 and 156:
ITEM PART NO. DESCRIPTION 1 2 3 4 V
Page 157 and 158:
Page 159 and 160:
ITEM PART NO. DESCRIPTION KAWASAKI
Page 161 and 162:
DIESEL ENGINE - CLOSED BREATHER 8 G
Page 163 and 164:
ITEM PART NO. DESCRIPTION 1 2 3 4 K
Page 165 and 166:
Page 167 and 168:
Page 169 and 170:
Page 171 and 172:
Page 173 and 174:
ITEM PART NO. DESCRIPTION 1 2 3 4 H
Page 175 and 176:
ITEM PART NO. DESCRIPTION 1 2 3 4 D
Page 177 and 178:
Page 179 and 180:
Page 181 and 182:
Page 183 and 184:
Page 185 and 186:
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
Page 193 and 194:
ITEM PART NO. DESCRIPTION 1 2 3 4 6
Page 195 and 196:
Page 197 and 198:
Page 199 and 200:
ITEM PART NO. DESCRIPTION 1 2 3 4 N
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
ITEM PART NO. DESCRIPTION 1 2 3 4 V
Page 207 and 208:
Page 209 and 210:
Page 211 and 212:
Page 213 and 214:
Page 215 and 216:
FUEL, INTAKE, & GOVERNOR SYSTEM 9 G
Page 217 and 218:
ITEM PART NO. DESCRIPTION FUEL SYST
Page 219 and 220:
Page 221 and 222:
Page 223 and 224:
Page 225 and 226:
CARBURETOR INSTALLATION - KAWASAKI
Page 227 and 228:
Page 229 and 230:
Page 231 and 232:
ITEM PART NO. DESCRIPTION 1 2 3 4 A
Page 233 and 234:
ITEM PART NO. DESCRIPTION 1 2 3 4 A
Page 235 and 236:
Page 237 and 238:
INTAKE DUCT AND AIR BOX ASSEMBLY -
Page 239 and 240:
CARBURETOR ASSEMBLY, KAWASAKI GASOL
Page 241 and 242:
EXHAUST SYSTEM 10 G E D
Page 243 and 244:
Page 245 and 246:
Page 247 and 248:
Page 249 and 250:
CLUTCHES 11 G E D
Page 251 and 252:
Page 253 and 254:
Page 255 and 256:
ITEM PART NO. DESCRIPTION QTY 1 2 3
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
Page 263 and 264:
Page 265 and 266:
Page 267 and 268:
Page 269 and 270:
DRIVETRAIN COMPONENTS 12 G E D
Page 271 and 272:
Page 273 and 274:
Page 275 and 276:
ITEM PART NO. DESCRIPTION FRONT DIF
Page 277 and 278:
Page 279 and 280:
Page 281 and 282:
ITEM PART NO. DESCRIPTION 1 2 3 4 T
Page 283 and 284:
Page 285 and 286:
ITEM PART NO. DESCRIPTION TRANSMISS
Page 287 and 288:
Page 289 and 290:
Page 291 and 292:
Page 293 and 294:
ITEM PART NO. DESCRIPTION TRANSMISS
Page 295 and 296:
TRANSMISSION - DIESEL VEHICLES, SHI
Page 297 and 298:
RADIATOR AND COOLANT SYSTEM - DIESE
Page 299 and 300:
Page 301 and 302:
Page 303 and 304:
Page 305 and 306:
COOLING SYSTEM CLAMPS, HOSES, AND H
Page 307 and 308:
Page 309 and 310:
Page 311 and 312:
Page 313 and 314:
MAINTENANCE AND SERVICE TOOLS 14 G
Page 315 and 316:
Page 317 and 318:
ITEM PART NO. DESCRIPTION MAINTENAN
Page 319 and 320:
Page 321 and 322:
Page 323:
Page 326 and 327:
INDEX 101879401 5-5 101879701 5-5 1
Page 328 and 329:
INDEX 102603801 8-27 102603901 8-27
Page 330 and 331:
INDEX 102728701 8-29 102728801 8-29
Page 332 and 333:
INDEX 103233614 3-11 103233617 3-11
Page 334 and 335:
INDEX rocker arm 8-45 seat back 1-2
Page 336 and 337:
INDEX fuel tank, gas 9-5 fuel-hour
Page 338 and 339:
INDEX pipe band 13-11, 13-15 pipe c
Page 340:
INDEX puller, special use 14-9 stee
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2009-2011 Carryall 295 / XRT 1550 - Mobilicab

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