2009 Kawasaki MULE 4010 4x4 Diesel Owners Manual

2009 Kawasaki MULE 4010 4x4 Diesel Manual

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  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 1
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 2
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 3
    ENGLISH j Utility Vehicle Owner's Manual
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    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION HOW TO OPERATE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j A Table of Contents is included after the Foreword.
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    or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. NOTE żThis note symbol indicates
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 7
    . As the owner of the Mule, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 8
    Tampering with Emission Control System is Prohibited Federal law and California state law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 9
    its features, capabilities, and limitations. To ensure a long, trouble-free life for your Mule, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their Mule, a Service Manual is available for purchase from any authorized Kawasaki
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    Bracket ...Winch Installation ...HOW TO OPERATE ...Daily Safety Checks ...Starting the Engine...Cold Weather Starting ...Starting After Fuel System Service ...Jump Starting ...Moving Off ...Braking ...Stopping the Engine ...Parking the Mule ...Hi-Lo Shifting...Reversing Gears ...2WD-4WD Shifting
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    Belts ...Headlight Beam ...Battery ...Fuse ...Power Steering System...Breaker ...General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 115 116 116 116 116 118 119 120 121 122 125 126
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    judgement. Practice basic maneuvers so you can drive confidently and safely. Read the Owner's Manual Read and understand this Owner's Manual. This is especially important for inexperienced drivers. Refer to this Owner's Manual if you have any questions. Off-Highway Use Only This vehicle is not an
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 13
    BASIC SAFE DRIVING 11 Protect Yourself, Use Proper Riding Gear As appropriate to your operating conditions, wear approved helmet, eye protection, and protective clothing. Operating in a recreational setting, like trail driving or any aggressive riding, could increase the risk of head injury, and
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    12 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius Differential Mode: Seating Capacity DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: Front Rear Ground Clearance Curb Mass Cargo Bed (L × W × H) ENGINE Type Displacement Bore × Stroke
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    SPECIFICATIONS 13 Engine Oil Engine Oil Capacity Coolant Capacity DRIVE TRAIN Driving Type Transmission Type Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio: API CF or CF-4 class SAE10W-40 3.3 L (3.5 US qt) 4.1 L (4.3 US qt) 4WD/2WD, gear 2-speed & reverse, automatic 3.7 ∼ 0.98 (
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    14 SPECIFICATIONS ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light LOAD CAPACITY Maximum Vehicle Load (Including occupants and cargo) Maximum Cargo Bed Load Specifications subject to change without notice. 12 V 52 Ah 12 V 35 W × 2 12 V 5/21 W × 2 740 kg (1 632 lb) 499 kg (1 100 lb)
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    SERIAL NUMBER LOCATIONS 15 SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the vehicle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 18
    16 LOCATION OF PARTS LOCATION OF PARTS 1. Headlights 2. Cab Frame 3. Front Cargo Hood 4. Front Cargo Compartment 5. Steering Wheel 6. Seat 7. Seat Belts 8. Front Bumper 9. Radiator 10. Parking Brake 11. Battery 12. Latch 13. Air Cleaner (Belt Drive Torque Converter) 14. Belt Drive Torque
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    LOCATION OF PARTS 17 16. Air Cleaner (Engine) 17. Screen 18. Tail Gate 19. Cargo Bed 20. Dashboard 21. Coolant Reserve Tank 22. Tail/Brake Lights 23. Trailer Hitch Bracket 24. Muffler (Spark Arrester) 25. Fuel Tank 26. Fuel Tank Cap
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    18 LOCATION OF PARTS 27. Left Glove Compartment 28. Light Switch 29. Front Cargo Hood Knob 30. Oil Pressure Warning Light 31. Coolant Temperature Warning Light 32. Speedometer 33. Parking Brake Warning Light 34. Glow Plug Light 35. Power Steering Warning Light 36. Hour Meter 37. Main Switch 38.
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    LOCATION OF LABELS 19 LOCATION OF LABELS 1. Warning (Off-Highway Utility Vehicle) 2. Caution (Shifting) 3. Warning (Front Cargo Hood) 4. Caution (Downhill Speed) 5. Warning (General) 6. Specification 7. Important Information (Tires/Max. Load) 8. Warning (Cargo Bed) 9. Cargo Bed Information 10.
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    20 LOCATION OF LABELS 11. Warning (Hot Surfaces) 12. Caution (Engine Oil Fill) 13. Caution (Engine Oil Level) 14. Important Engine Information 15. Warning (Towing Bracket) 16. Warning (Refueling)
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    LOCATION OF LABELS 21 (1) (3) (2) (4)
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    22 LOCATION OF LABELS (5)
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    LOCATION OF LABELS 23 (6) (8) (7) (9)
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    24 LOCATION OF LABELS (10) (11) (12)
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    LOCATION OF LABELS 25 (13) (14)
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    26 LOCATION OF LABELS (15)
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    LOCATION OF LABELS 27 (16) (18) (17) (19)
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    the vehicle is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has front body work and fenders are not designed to carry cargo or to support your weight. They may break. Because any vehicle is sensitive to
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 31
    LOADING INFORMATION 29 subtract trailer tongue weight from the • Always Maximum Load capacity. Refer to the "Trailer Hitch Bracket" section in the "General Information" chapter. Maximum Load Weight of operator, passenger, and cargo must not exceed 740 kg (1 630 lb). vehicle is not designed to carry
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    or aftermarket cetane improver additives to diesel fuel. Damage to the fuel injection system may result. Engine Oil Use only oils conforming to API Service CF or CF -4. Use the proper SAE viscosity grade of engine oil for the expected ambient temperature range as indicated in the following chart
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 33
    GENERAL INFORMATION 31 Lighting/Electrical Accessory Connectors The lighting 12 volt connector is located on the dashboard. An auxiliary light may be connected to this connector. Other connectors for electrical accessory are located under the left side dashboard. Optional items such as wiper and
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 34
    32 GENERAL INFORMATION j Brake Pedal The brake pedal is the left pedal on the foot board. Depress the pedal to slow or stop the vehicle. Cargo Bed For loading and unloading, the tail gate of the cargo bed can be opened. Raise the latch handles at each end of the tail gate and slide both latches
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 35
    GENERAL INFORMATION 33 the handgrips. Support the bed in the tilted position with the rod. j A. Supporting Rod A. Latch B. Handgrip CAUTION Do not carry more than the maximum load stated here in the cargo bed. Maximum Load: 499 kg (1 100 lb)
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    34 GENERAL INFORMATION j WARNING Overloading or improper use of the cargo bed can cause changes in handling which can lead to an accident. Follow guidelines provided in the "LOADING INFORMATION" chapter. Passengers riding in the cargo bed can be tossed about or even thrown out causing serious
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 37
    GENERAL INFORMATION 35 Coolant Temperature Warning Light The coolant temperature warning light (TEMP) comes on whenever the coolant temperature rises too high while the vehicle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools
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    36 GENERAL INFORMATION j Fuel Tank The fuel tank is mounted under the right side of the cargo bed. This engine is certified to operate on Diesel Fuel. Use clean, fresh diesel fuel (ASTM D975) for good performance of this vehicle. Avoid refilling the tank in the rain or where heavy dust is blowing,
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    GENERAL INFORMATION 37 CAUTION Do not use gasoline, gasohol or any other fuel, except diesel fuel. Improper fuel can cause severe fuel injection system and engine damage. j Fuel Gauge The fuel gauge on the fuel tank shows the amount of fuel in the fuel tank. When the red indicator needle comes
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 40
    the air cleaner is clogged. The air cleaner element should be cleaned if the restriction gauge window band changes from yellow to red. After servicing the air cleaner element, the restriction gauge should be reset by pushing the button at the end of the gauge. Glove Compartment A glove compartment
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 41
    GENERAL INFORMATION 39 j Front Cargo Compartment The front cargo compartment is located under the front cargo hood. Store only light-weight items in it to avoid damage to the inside of the compartment. Do not put items which must not get wet or dirty in it. A. Right Glove Compartment A. Front
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    40 GENERAL INFORMATION j A. Latch Release Knob A. Push here. B. Latches NOTE żWhen the hood is hard to open, pull and lift up the front hood center portion with pulling the knob to open the hood. Hood Closing Close the hood until it locks. After the hood is closed, push the two parts of the
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    GENERAL INFORMATION 41 j Horn Button A car-type horn button is provided on the center of the steering wheel. Push the horn button to sound the horn. Main Switch This is a three-position, key-operated switch. The key can be removed from the switch only when it is in the "OFF" position. A. Horn
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    42 GENERAL INFORMATION OFF ON Engine off. All electrical circuits off. All electrical equipment can be used. Hour meter works. Electric starter is engaged by holding main switch key in this position, only when gear shift lever is in "N" (neutral) position. Upon release, key will return to "ON"
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 45
    GENERAL INFORMATION 43 j Light Switch Turn on the headlights and taillights by pushing the light switch in, with the main switch key in the "ON" position. The lights go off when the switch is pushed out. Speedometer The speedometer shows the speed of the vehicle. In the speedometer face is the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 46
    44 GENERAL INFORMATION j Oil Pressure Warning Light The oil pressure warning light goes on whenever the oil pressure is dangerously low or the main key is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. CAUTION If the engine oil gets
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 47
    GENERAL INFORMATION 45 j Shift Levers This vehicle is equipped with three different shift levers: the gear shift lever, the 2WD-4WD shift lever and the differential shift lever. Gear Shift Lever The gear shift lever is located on the dashboard, to the right of the steering shaft. The gear shift
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 48
    46 GENERAL INFORMATION raises the speed range for ordinary off-highway use. Stop the vehicle before moving the Hi-Lo shift lever. j CAUTION Use of the high range for heavy loads, climbing hills, and pulling a trailer can lead to premature wear of the torque converter belt and pulleys. Use low
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    GENERAL INFORMATION 47 Differential Shift Lever This vehicle is equipped with a dual-mode rear differential. The differential shift lever is located on the dashboard, to the left of the steering shaft. Move the shift lever up or down as indicated on the label next to the shift lever. Refer to the "
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    48 GENERAL INFORMATION j WARNING Be sure to apply the parking brake before leaving the vehicle. If the vehicle should move, it might be damaged or cause injury. Parking Brake Warning Light The parking brake warning light goes on when the parking brake is applied with the main switch in the "ON"
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    GENERAL INFORMATION 49 j Seat The seat can be raised for vehicle maintenance and adjustment. Pull up on the rear edge of the seat. Seat Belts The vehicle is equipped with lap-style seat belts both for the operator and passenger. Always wear the seat belts when operating and riding in the vehicle.
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    50 GENERAL INFORMATION To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Adjust the seat belt for a SNUG FIT. j WARNING
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    fittings of steering actuator, or the neutral position setting of the steering will be adversely affected and will cause serious driving problems. If such components need service, see an authorized Kawasaki dealer. If the steering becomes more difficult than usual or you experience other steering
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    procedure. A. Power Steering Warning Light A. Throttle Pedal NOTE żIf the warning light does not go on when the main switch is "ON", there may be a problem with the light itself. See a dealer for inspection.
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    GENERAL INFORMATION 53 j Trailer Hitch Bracket This vehicle is equipped with a bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, observe the following precautions: WARNING Never carry a passenger in a trailer. Never load
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    54 GENERAL INFORMATION 2. j Winch Installation Installing procedure for a winch 1. Remove the front bumper cover screws, and front bumper cover. Remove the front bumper and side plate to gain access by releasing bolts and screws. A. Front Bumper B. Bolts C. Winch Bracket A. Front Bumper Cover B.
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    GENERAL INFORMATION 55 3. You can see the bracket attached to a cross -member. j A. Side Plate B. Screws A. Winch Bracket 4. 5. Follow a manual to be supplied by the winch maker for installing the winch and other accessory as necessary. After installing the winch, be sure to re-install
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    . If any irregularities are found during 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. j WARNING Failure to perform these checks every day before operation
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 59
    HOW TO OPERATE 57 Throttle ...Throttle pedal free play 5 ∼ 10 mm (0.2 ∼ 0.4 in.). Throttle pedal operates smoothly and returns to rest position when released. Steering ...Steering wheel free play 0 ∼ 20 mm (0 ∼ 0.8 in.). Action smooth without excessive play, rough spots, or strange noises. Brakes
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    58 HOW TO OPERATE Starting the Engine CAUTION Do not operate the electric starter continuously for more than 5 seconds, or the starter may overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and for the battery to recover power
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    ON again. Repeat this 2 or 3 times to thoroughly preheat the combustion chambers. Finally, crank the engine to start it. Starting After Fuel System Service Air bleeding of the fuel system may be required before engine starting if air was introduced into the fuel system during maintenance. (Fuel
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    60 HOW TO OPERATE Jump Starting If your vehicle battery is "run down," it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. j WARNING Battery acid generates hydrogen gas which is flammable and explosive under
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    HOW TO OPERATE 61 j A. Battery B. Cap Cover a jumper cable from the positive (+) ter• Connect minal of the booster battery to the positive (+) terminal of the vehicle battery. A. Vehicle Battery Positive (+) Terminal B. From Booster Battery Positive (+) Terminal C. Unpainted Metal Surface D.
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    62 HOW TO OPERATE WARNING Do not make this last connection at the carburetor or battery. Take care not to touch the positive and negative cables together, and do not lean over the battery when making this last connection. Do not connect to a frozen battery. It could explode. Do not reverse polarity
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    HOW TO OPERATE 63 Braking NOTE Stopping the Engine the throttle pedal completely. • Release Put the gear shift lever into the "N" (Neutral) posi• tion. the parking brake to help prevent the vehicle • Apply from rolling. • Turn the main switch key to the "OFF" position. j żWhen the throttle pedal
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 66
    64 HOW TO OPERATE Parking the Mule WARNING Be sure to apply the parking brake before leaving the vehicle. If the vehicle should move, it might be damaged or cause injury. the main switch key to prevent unautho• Remove rized use. parking inside a garage or other structure, • When be sure the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 67
    HOW TO OPERATE 65 Hi-Lo Shifting Shifting to Low Range the vehicle completely. • Stop easy Hi-Lo shifting, put the gear shift lever in • For neutral. • Move the shift lever "L" (Low) position. Shifting to High Range the vehicle completely. • Stop Put the gear shift lever in neutral. • Move the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 68
    66 HOW TO OPERATE Reversing Gears the throttle pedal, and stop the vehicle. • Release When you want to operate the vehicle in reverse, • stop the vehicle completely, allowing the engine to slow to idling speed, and move the gear shift lever to the "R" (Reverse) position. 2WD-4WD Shifting the
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    HOW TO OPERATE 67 Shifting the Differential NOTE j żDo not operate the differential shift lever if the vehicle is moving faster than 8 km/h (5 mph). Shifting to Locked-Axle Mode the stopper under the differential shift lever • Pull knob and while holding it against the knob, move the shift
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    68 HOW TO OPERATE Shifting to Differential (Unlocked-Axle) Mode and hold the stopper, then move the shift lever • Pull all the way up (UN-LOCK). j NOTE żWhen the shift lever is moved, the differential may not immediately lock or unlock until the vehicle has rolled a short distance.
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    your vehicle may result in an unsafe operating condition. Before operation, make sure that the vehicle is not overloaded and that you have followed the instructions in the "Loading Information" chapter.
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    70 SAFE OPERATION Driving in Reverse Start the engine following the procedure in the "Starting the Engine" section. Before shifting into reverse, stop the vehicle completely. Refer to the Gear Shift Lever in the "Shift Levers" section and "Reversing Gears" section. Turn around and look behind you
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    SAFE OPERATION 71 Turning the Vehicle The vehicle will turn in a smaller radius with the differential unlocked (in differential mode). In this mode, the rear wheels can turn at different speeds allowing the vehicle to turn tighter and more smoothly. Even in this mode, however, avoid sharp turns to
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    72 SAFE OPERATION Climbing Hills Do not attempt to climb hills or steep inclines until you have mastered the controls and basic operating maneuvers of this vehicle. Always go straight uphill and, if the incline is steep and/or the surface is loose, use "4WD" with the differential locked for greater
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    SAFE OPERATION 73 Descending Hills Slow down or stop at the top of a hill so you can pick a straight, safe path for descent to avoid any obstacles. Normally you should descend straight down a hill since driving at an angle could cause the vehicle to lean to one side and possibly tip over. Proceed
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    74 SAFE OPERATION Traversing Hillsides When driving across the side of a hill, reduce vehicle speed and exercise extreme caution to prevent tipping or loss of control. Avoid hills with slippery sides that will cause you to lose traction. Also avoid traversing hillsides covered with rocks or other
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    SAFE OPERATION 75 Driving through Water Avoid driving through water whenever it is possible. When driving across shallow water, choose a location to enter and exit the water where the banks are not too steep or slippery. Check before entering for rocks, holes or other obstacles which may cause you
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    76 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the Mule in good running condition. The initial maintenance is vitally important and
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    drive belt deflection -inspect* Converter driven pulley shoe -inspect* Converter air cleaner element -clean* Valve clearance-inspect Engine oil-change* 1 year D D D Regular Service • j Every Every Every 800 After 50 Every 100 hrs. or 250 hrs. 500 hrs. hrs. or hrs. or 1,000 km 2,000 km or 5,000
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    element - change* Fuel filter water - drain* Fuel hoses and connections-inspect * Spark arrester-clean Radiator-clean* Radiator hoses and connections-inspect* 1 year D Regular Service Every Every Every After 50 Every 100 hrs. or 250 hrs. 500 hrs. 800 hrs. hrs. or 1,000 km 2,000 km or 5,000 or 10
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    level-inspect Parking brake lever-inspect Brake hose and pipe-inspect Brake wear-inspect* Tire wear-inspect* Battery-inspect Brake light switch-inspect 2 years (D) D Regular Service Every Every Every After 50 Every 100 hrs. or 250 hrs. 500 hrs. 800 hrs. hrs. or 1,000 km 2,000 km or 5,000 or 10
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    -change Brake master cylinder cup and dust seal-replace Brake wheel cylinder assembly -replace Brake hose-replace 1 year 2 years (D) 2 years (D) 2 years (D) 4 years (D) D Regular Service Every Every Every After 50 Every 100 hrs. or 250 hrs. 500 hrs. 800 hrs. hrs. or 1,000 km 2,000 km or 5,000 or 10
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 Engine Oil In order for the engine to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Chart. Not only do dirt and metal particles collect in the oil, but the oil itself loses
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    82 MAINTENANCE AND ADJUSTMENT j A. Dipstick B. F (Full) Hole C. L (Low) Hole A. Oil Filler Cap Oil and/or Oil Filter Change When changing or adding oil, use the chart on page 85 to select the correct viscosity grade for the temperature expected. Warm up the engine thoroughly, and then stop the
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    MAINTENANCE AND ADJUSTMENT 83 j A. Drain Plug A. Cartridge • Let the oil drain completely. WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. the oil filter is to be changed, remove the oil
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    84 MAINTENANCE AND ADJUSTMENT j A. Gasket the engine up to the F (full) hole on the dipstick • Fill with good quality engine oil as specified in the fol- A. Dipstick Tube B. about 5 cm or 2 inches C. Funnel • lowing table. Start the engine and check for oil leakage. NOTE NOTE żPark the
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    MAINTENANCE AND ADJUSTMENT 85 CAUTION If the oil level in the cylinder head cover gets too high because of filling too fast or filling too much (overfilling), oil may overflow from the filler hole and/or may flow through the crankcase ventilation tube into the intake manifold. Oil in the intake
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    86 MAINTENANCE AND ADJUSTMENT Front Final Gear Case Oil In order for the differential, pinion, and ring gears to function properly, check the oil level and change the oil in accordance with the Periodic Maintenance Chart. j WARNING Vehicle operation with insufficient, deteriorated, or
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    MAINTENANCE AND ADJUSTMENT 87 the vehicle level front-to-rear and side-to • With -side, remove the filler cap from the front final gear case. j A. B. C. D. A. Front Final Gear Case B. Filler Cap Front Final Gear Case Filler Opening Bottom Thread Drain Plug CAUTION Be careful not to allow any
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    88 MAINTENANCE AND ADJUSTMENT Oil Change NOTE WARNING When draining or filling the gear case, be careful that no oil gets on the tires or rims. Oil on tires can make them slippery which can cause an accident and injury. Clean off any oil that inadvertently gets on them with soap and water. the oil
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    • Pull oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. • • • Park the vehicle on level ground. Lift the cargo bed and support it with the rod. Unscrew the oil filler plug, wipe its dipstick dry, and insert it into the filler hole but DO NOT SCREW IT
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    case. A. Transmission Case B. Drain Plug WARNING To avoid a serious burn, never touch a hot muffler or exhaust pipe during oil draining. • Lift the cargo bed and support it with the rod.
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    MAINTENANCE AND ADJUSTMENT 91 • Remove the filler plug. WARNING When draining or filling the transmission case, be careful that no oil gets on the tires or rims. Oil on tires can make them slippery which can cause an accident and injury. Clean off any oil that inadvertently gets on them with soap
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT Cooling System WARNING Do not touch the radiators when they are hot, nor open the radiator caps. Hot coolant inside will cause you severe burns. Radiator Lift the front cargo hood up. Refer to the "Front Cargo Compartment" section in the "General Information" chapter
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 CAUTION Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator's effectiveness. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator or behind the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT the filler opening to the "F" (Full) mark. Install the cap. Recommended Coolant Solution Coolant Mixture Ratio: Water 50%: Antifreeze 50% (1 : 1) Recommended Antifreeze: Permanent type antifreeze (ethylene glycol plus corrosion and rust inhibitor chemicals for cast-iron
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 97
    gauge shows whether the air cleaner is clogged. Whenever the red band shows in the gauge window, the air cleaner element should be cleaned. After servicing the air cleaner element, the restriction gauge should be reset by pushing the button at the end of the gauge. j
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 98
    96 MAINTENANCE AND ADJUSTMENT j A. Air Filter Restriction Gauge Element Removal A. Air Cleaner Housing B. Cap C. Snaps the seat. • Raise Pull up snaps and remove the air cleaner hous• ing capthe from the housing. the air cleaner element out of the housing. • Pull Push a clean, lint-free towel
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 Element Cleaning the element (see Element Removal). • Remove Clean the paper element by tapping it lightly to • loosen dust. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the the element material for damage. If any •
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 100
    98 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a spark arrester approved for off-highway use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. Clean the spark arrester in accordance with the Periodic Maintenance Chart. j CAUTION The
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 the engine. • Stop Install the drain plug. • Throttle Pedal If the throttle pedal has excessive play due to either cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT j A. Throttle Pedal B. 5 ∼ 10 mm (0.2 ∼ 0.4 in.) A. Throttle Cable Adjuster B. Mounting Nuts Throttle Pedal Play Adjustment the cargo bed and support it with the rod. • Lift the adjuster mounting nuts at the end of • Loosen the throttle cable. the adjuster until the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 103
    contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the cargo bed and support it with the rod. • Lift Use tachometer to measure the idle • RPM.a Ifsuitable it does not match the specification, pro- • ceed
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT j A. Cover Bolts B. Pump Cover the locknut and the accelerator lever stop• Loosen per screw on the injection pump. A. Accelerator Lever Stopper Screw B. Locknut C. Accelerator Lever the idle speed by turning the accelerator • Adjust lever stopper screw. Idle Speed
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 Fuel Filter Accumulation of moisture or sediment in the fuel system can restrict the flow of fuel and cause injection pump damage. The system should be checked in accordance with the Periodic Maintenance Chart. the air vent plug counterclockwise several • Open turns.
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 106
    104 MAINTENANCE AND ADJUSTMENT a suitable container under the fuel filter to • Place catch spilled fuel. the drain cap at the bottom end of the fuel • Remove filter. Discard the O-ring. the fuel filter element with a filter wrench. • Remove Replace old filter element with a new one. • Tighten it the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 Fuel Tank Vent The fuel tank vent hoses must be routed as specified. The engine may stall or lose power if the fuel tank vent is plugged or if the vent hoses are pinched. Inspect the vent hoses before riding and whenever the engine seems to lose power. If the fuel
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 108
    106 MAINTENANCE AND ADJUSTMENT Belt Drive Torque Converter Air Cleaner A clogged belt drive torque converter air cleaner may cause the torque converter to malfunction. CAUTION A clogged air cleaner may allow dirt and dust to enter the belt drive torque converter causing excessive wear of the inner
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 CAUTION If dirt gets into the belt drive torque converter, excessive wear and loss of driving power may result. away the remaining dust by applying com• Blow pressed air from the inside to the outside (from the the element material for damage. If any • Inspect part
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT Brakes The vehicle is equipped with hydraulically activated drum brakes on all four wheels. Brake Pedal the brake pedal has more or less free play • If than specified or the pedal action feels rough or "catchy," have the brake system inspected immediately by an
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 111
    MAINTENANCE AND ADJUSTMENT 109 WARNING Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in the brakes. This lowers the brake fluid boiling point and could reduce brake
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 112
    lines or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, have the brake system serviced immediately. j Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. A. Brake Fluid Reservoir B. Cargo Compartment Wall WARNING Change the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 Brake Light Switch When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. Adjustment is best-performed by an authorized • Adjustment Kawasaki dealer since the brake
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 114
    112 MAINTENANCE AND ADJUSTMENT Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check that the parking brake lever functions properly. the parking brake lever up and to the rear. • Pull After to 12 clicks of
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 115
    MAINTENANCE AND ADJUSTMENT 113 Steering Wheel In accordance with the Periodic Maintenance Chart, check the steering wheel for the specified free play and smooth operation. Free Play Inspection A. Locknut B. Nut the vehicle on level ground. • Park turn the steering wheel left and right. • Lightly
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 116
    happen when the engine starts; inspect the battery voltage. Cable harness or connectors may have been disconnected. See an authorized dealer for service. • • • • j NOTE żIf the steering becomes irregular or unusual for A. Steering Column Bracket B. Nuts any reason other than above, have an
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 Cargo Bed Latches • Retighten the mounting bolts. NOTE żAdjustment must be made on both sides. j A. Cargo Bed Hook B. Latch and Lever C. Mounting Bolts Cargo bed latches must rest securely on the cargo bed hooks without rattling. If there is rattling or not snug
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 118
    change or impair the handling of the vehicle. żInstallation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. Nevertheless, a tube can be inserted into the tire by the operator as an emergency repair. Maximum Tire Air Pressure for Seating
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 WARNING Inflate both front tires to the same pressure and both rear tires to the same pressure. Operating with unequally or improperly pressurized tires can adversely affect steering or handling. Minimum Tread Depth: 3 mm (0.12 in.) inspect the tire for cracks and
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT Joint Boots In accordance with the Periodic Maintenance Chart, inspect the joint boots on the front axles, tie rod ends, steering knuckles, and rear axle shafts for cracks, holes, damage or deterioration. If there is any one of them, have the joint boot replaced by an
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 Suspension j A. Adjusting Sleeve B. Turn here with a hook wrench A. Shock Absorber B. Adjusting Sleeve Rear Shock Absorber Spring Force Adjustment The spring adjusting sleeves on the rear shock absorbers have 5 positions so that the springs can be adjusted for
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 122
    120 MAINTENANCE AND ADJUSTMENT WARNING Improper shock absorber adjustment can cause poor handling and loss of stability, which could lead to an accident. Always adjust the shock absorbers on the left and right side to the same setting. Seat Belts In accordance with the Periodic Maintenance Chart,
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 Headlight Beam • The headlight beams can be adjusted vertically. Remove the holder. j A. Adjusting Screws A. Holder the adjusting screw on each headlight rim in • Turn or out to adjust the headlight vertically.
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 124
    122 MAINTENANCE AND ADJUSTMENT Battery The battery is located under the left end of the seat. WARNING Heed the battery safety label shown here. j A. Holder B. (+) Terminal C. (-) Terminal the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. the
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 125
    to a sealed type battery. The sealing strip should never be removed after the specified electrolyte has been installed in the battery for initial services. However, in order to maximize battery life and ensure that it will provide the power needed to start your vehicle you must properly maintain
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 126
    124 MAINTENANCE AND ADJUSTMENT Self-discharge Approx. Number of Days From 100% Charged to 100% Discharged Lead-Antimony Battery 40°C (104°F) 25°C (77°F) 0°C (32°F) 100 Days 200 Days 550 Days Lead-Calcium Battery 300 Days 600 Days 950 Days Battery Sulfation A common cause of battery failure is
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 127
    battery in this vehicle, or the electrical system cannot work properly. NOTE żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery and charger. WARNING Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 128
    blown, steering becomes heavy. Replace the blown fuse with a fuse of the same specific amperage and type. If a replaced fuse blows again, there can be trouble with the ECU or harness/connectors. See an authorized dealer for inspection. You can check the 40 A fuse if it is blown at the top
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 129
    MAINTENANCE AND ADJUSTMENT 127 Breaker The breaker for the radiator fan is located under the seat near the fuse box. If the fan does not function, inspect the breaker. In order to reset the breaker, push the button at the side of the breaker case. Before resetting, however, check that the radiator
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 130
    In accordance with the Periodic Maintenance Chart, have the general lubrication performed by an authorized Kawasaki dealer or perform it referring to the Service Manual for this vehicle. Cleaning To prolong the life of your vehicle, wash it down immediately after it has been splashed with sea water
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 131
    MAINTENANCE AND ADJUSTMENT 129 CAUTION Coin operated, high pressure spray washers are not recommended. Water may be forced into bearings and other components causing eventual failure from rust and corrosion. Some soaps are highly alkaline and may leave a residue or cause spotting. Bolt and Nut
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 132
    żAs an alternative to draining the fuel system, a fuel stabilizer designed specifically for diesel fuel may be used. follow the manufacturer's instructions for use. j WARNING Fuel stabilizers may contain poisonous substances. Heed the manufacturer's warnings for use. each cylinder with 3 cc engine
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 133
    STORAGE 131 • Reattach the fuel solenoid switch connector. j A. Glow Plugs NOTE A. Fuel Solenoid Switch Connector żDo not use more than 3 cc of engine oil in each cylinder. Too much oil could cause hydraulic lock and engine damage. • Install the glow plugs. Tightening Torque Glow Plug: 17 N·m
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 134
    132 STORAGE CAUTION Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged a battery becomes, the more easily it freezes. a plastic bag over the exhaust pipe and air • Tie cleaner inlet (rear cab frame top) to
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 135
    TROUBLESHOOTING GUIDE 133 TROUBLESHOOTING GUIDE Starter Motor Won't Turn Fuse failed (be sure to check for or inlet blocked • Air oil incorrect • Engine Water in fuel • Drive train trouble • Power Steering Won't Work ECU functioned to prevent overheating. Fuse failed Battery discharged Cable
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 136
    of your WRITTEN correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through WRITTEN correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 137
    ENVIRONMENTAL PROTECTION 135 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 138
    136 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 139
    MAINTENANCE RECORD 137 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 140
    138 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 141
    MAINTENANCE RECORD 139 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 142
    140 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 143
    MAINTENANCE RECORD 141 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 144
    142 MAINTENANCE RECORD WARNING WARNINGS indicate a potential hazard that could result in personal injury or death.
  • 2009 Kawasaki MULE 4010 4x4 Diesel | Owners Manual - Page 145
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